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LO215 Production Orders LO215
Release 640 04/06/2006
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SAP AG 1999
LO215 Production Orders
SAP AG
LO215LO215
Production OrdersProduction Orders
System R/3 Release 4.6C October 2000 5004 2355
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SAP AG 2004
Copyright 2004 SAP AG. All rights reserved.No part of this publication may be reproduced or t ransmit ted inany form or for any purpose without the express permission ofSAP AG. The information contained herein may be changedwithout prior notice.
Copyright
Some software products marketed by SAP AG and its distributors contain proprietary software components ofother software vendors.
Microsoft, Windows, Outlook, and PowerPoint are registered trademarks of Microsoft Corporation. IBM, DB2, DB2 Universal Database, OS/2, Parallel Sysplex, MVS/ESA, AIX, S/390, AS/400, OS/390, OS/400,
iSeries, pSeries, xSeries, zSeries, z/OS, AFP, Intelligent Miner, WebSphere, Netfinity, Tivoli, and Informix aretrademarks or registered trademarks of IBM Corporation in the United States and/or other countries.
Oracle is a registered trademark of Oracle Corporation. UNIX, X/Open, OSF/1, and Motif are registered trademarks of the Open Group. Citrix, ICA, Program Neighborhood, MetaFrame, WinFrame, VideoFrame, and MultiWin are trademarks or
registered trademarks of Citrix Systems, Inc. HTML, XML, XHTML and W3C are trademarks or registered trademarks of W3C, World Wide Web
Consortium, Massachusetts Institute of Technology.
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MaxDB is a trademark of MySQL AB, Sweden. SAP, R/3, mySAP, mySAP.com, xApps, xApp, and other SAP products and services mentioned herein as well as
their respective logos are trademarks or registered trademarks of SAP AG in Germany and in several othercountries all over the world. All other product and service names mentioned are the trademarks of their respectivecompanies. Data contained in this document serves informational purposes only. National product specificationsmay vary.
These materials are subject to change without notice. These materials are provided by SAP AG and its affiliatedcompanies ("SAP Group") for informational purposes only, without representation or warranty of any kind, andSAP Group shall not be liable for errors or omissions with respect to the materials. The only warranties for SAP
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Group products and services are those that are set forth in the express warranty statements accompanying such
products and services, if any. Nothing herein should be construed as constituting an additional warranty.
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Production Planning
Level 2 Level 3
ManufacturingPlanning &Execution for Discrete & Repetitive
LO050 5 days
EngineeringChangeManagement
LO980 3 days
BatchManagement
LO955 3 days
KANBAN
LO235 2 days
Classification
LO985 3 days
Special Features ofLIS in Production
LO275 2 days
Logistics InfoPlanning
LO935 2 days
CAP Calculation of Standard Values
LO720 2 daysRepetitiveManufacturing
LO225 3 days
Capacity Planning
LO230 5 days
LogisticsInformationSystem (LIS)Reporting
LO930 2 days
Basic DataPart 2
LO206 3 daysBasic Data forDiscreteManufacturing
LO205 3 days
ProductionOrders
LO215 5 days
ProductionPlanning
LO210 5 days
VariantConfiguration Part 1
LO990 5 days
VariantConfiguration Part 2
LO991 3 days
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Requirements
Necessary: Knowledge of Production Planning andControl
LO205 Basic Data for DiscreteManufacturing
LO206 Basic Data Part 2
Recommended: LO050 Manufacturing Planning andExecution for Discrete and Repetitive
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Target Group
Members of the project team who are responsiblefor the implementation of production orders(consultants and administrators)Managers and employees in production areas(production schedulers, controllers, supervisorsand operators)
Duration: 5 days
Information for participants The training materials are not designed to be a self-teach program. They are only complete when used in
conjunction with the explanations of the instructor. You are given space on each page of the trainingmaterials to write down this additional information.
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At the conclusion of th is course, you will beable to:
Course Goal
SAP AG 1999
Use product ion orders.
Create, release and fully implementproduction orders. You will be able tomake system settings and also understandproduction orders in context.
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Classify production orders in the production planning andexecution environment (demand management, requirementsand materials planning, sales order processing and so on)Implement or apply production orders and their mostimportant functionsUnderstand and use the basic order management functionsin detailUse the information systems for production orders
Take into consideration the integration relationships withinthe production order Teach yourself additional special functions
Course Objective(s)
At the conclusion of this course, you will be able to:
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Unit 8 Order Control
Unit 9 Confirmations
Unit 10 Goods Receipt
Unit 11 Settlement, Archivingand Deletion
Unit 12 Information Systems
Unit 13 Mass Processing and
AutomationUnit 14 Collective Orders
Unit 1 Introduction
Unit 2 Overview
Unit 3 Order Structure /Processing
Unit 4 Order Creation /Order Change
Unit 5 Order Release
Unit 6 Printing Order DocumentsUnit 7 Material Staging
Preface
Appendix
Course Content
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Course Overview Diagram (1)
Goods ReceiptGoods Receipt 1010
ConfirmationsConfirmations 99
Information SystemsInformation Systems
1212
SettlementSettlement ,, Archiv ing Archiv ingandand DeletionDeletion 1111
CollectiveCollective OrdersOrders 1414
Mass ProcessingMass Processingand Automationand Automation 1313
MaterialMaterial StagingStaging 77
111
Order Order StructureStructure //ProcessingProcessing 33
Order Contro lOrder Contro l 88
PrintingPrintingOrder Order DocumentsDocuments 66
Order ReleaseOrder Release
55
Order Order CreationCreation //Order ChangeOrder Change 44
OverviewOverview 22
Introduction
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Overview: Contents
Overview of the process chain for order-related productionThe process chain in other production planning andcontrol scenarios
Characteristics of order-related production
Order-related production in the organization structures ofthe R/3 System
Master data prerequisites for production orders
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At the conclusion of th is un it you will be ableto :
Overview: Topic Objectives
SAP AG 1999
Recognize the different steps in the process chain fororder-related production
Recognize the most important characteristics of order-related production
Define how production orders are classified in the R/3application component PP and in the organizationstructures
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Goods ReceiptGoods Receipt 1010
ConfirmationsConfirmations 99
Information SystemsInformation Systems
1212
SettlementSettlement ,, Archiv ing Archiv ingandand DeletionDeletion 1111
CollectiveCollective OrdersOrders 1414
Mass ProcessingMass Processingand Automationand Automation 1313
MaterialMaterial StagingStaging 77
Order Contro lOrder Contro l 88
PrintingPrintingOrder Order DocumentsDocuments 66
Order ReleaseOrder Release
55
Order Order CreationCreation //Order ChangeOrder Change 44
Overview Diagram (2)
IntroductionIntroduction 11
22
Order Order StructureStructure //ProcessingProcessing 33
OverviewOverview
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Subsystems of the PP Application
PPPP
PPPC
Prod. Costing
PPIS
Prod. InfoSystem
PPMRP
Mat. RqmtsPlanning
PPSOP
Sales & Oper.Planning
PPMPS
DemandMgmt
PPBD
BasicData
PPPPSFCSFC
ShopShop Floor Floor ControlControl
PPPI
ProcessMfg
PPREMRep.Mfg
PPCRP
CapacityPlanning
PPKANKANBAN
The Production Planning (PP) application incorporates a number of integrated working subsystems . Each time you use the R/3 system, you should determine precisely which components are appropriate
to your needs. PP-Shop Floor Control is the subsystem for order-related production .
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Order-Related Production: Characteristics (1)
Order-related productionBased on production orders with order category '10'
Production by order lot sizes (see Lot-Sizing Procedure)
Integrated logistical and controlling functionality
Production by production versions (for example,production lines)
Detailed status management
Full integration into capacity planningPDC - Interface (PP-PDC) for download and upload
Material staging control led by material reservations
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Order-Related Production: Characteristics (2)
Availability checks for material, capacity, production resourcesand tools
Various options for entering actual data (quantity, time)
Order, operation, time event and progress confirmations
Extensive order-related or product-related controlling
Full integration in the Logistics Information System (LIS) andBusiness Information Warehouse (BW)
Archiving and retrieval funct ionNumerous special functions
multi-level collective orders, trigger points, serial numbers, ordersplit, external processing, rework, WIP, variance calculation,cross-plant production, batch creation and batch determination,co-products and so on
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Cross-Application Functions
Material forecast Sales & Distribution
Inventory
E A C D
B
C a p a c
i t y p
l a n n
i n g
C a p a c
i t y p
l a n n
i n g
C o s
t i n g
C o s
t i n g
Demand program Sales reqmtsPlanning
Requirements planning
Production order Production order
Order Order processingprocessing
Goods receiptGoods receipt
Order Order settlementsettlement
Goods issueGoods issue
Purchase requisition
Purch ase order
Goods receipt
Invoice receipt
Planned order Planned o rder
Production order management is a central component of a complex process chain that starts withindependent requirements (planned or customer requirements) and ends in the issue of a finished
product. Production order management in the SAP System only controls the whole process of in-house
production . Production order management uses the following system components :
ALE, Workflow, Customizing, word processing, factory calendar, classification, communication andgraphics.
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Production Planning and Control Data
Confirmations
CO object (cost col lector)
Material movements (goods receipt / issue)
Production orders
Factory calendar
Mat. master
Work centers
Bills of material
Routings
Prod. resources/tools
CAPP formulas
Documents
Master Master datadata
TransactionTransaction datadata
Data that does not change frequently is defined as master data of the Production Planning System. Transaction data are documents that have a restricted time application. In the Production Planning
System these are production orders. Documents for confirmations, costs (CO objects) and material movements are assigned to the production
orders.
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Corporate Order Management
Order
Assign mentto a
material
Order Order Order
Overheadcost
orders
Capitalinvestment
orders
Goods for the market Internal company goods and services
Sales-Related
Goodssold
Goods instock
Company Internal
Cannot b eactivated Can be activated
Customer Warehouse Cost center Asset portfolio
Logi sti c f un ctio ns (qu ant iti es and v alues) Cost ac cou nti ng fun cti ons (v alues)
Assign mentto a
sales order
Corporate order management is divided into two basic forms : Sales-related orders and companyinternal orders .
Within company internal orders, a distinction has to be made between:Orders purely for object control within cost accounting (for example, for promotional purposes orfor use in trade fairs). Productive and value-added orders that can be activated (for example, for in-house production on a production line).
In the R/3 System, both basic order forms are assigned to SAP applications via order category . Examples: Production order (PPS) -> PP Production Planning
Plant maintenance order -> PM Plant Maintenance Network -> PS Project SystemOverhead cost order -> CO Controlling
Capital investment order -> CO Controlling
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Document Type, Order Category, Order Type
Material accounting documentsFinancial accounting documents
Orders
PP process order PS networkCO internal order CO production order CO model order PM plant maintenance order
Produ ction or der (external number range)Production order (special types)
Production order (internal number range)
PP production order
Document typ eDocument typ e
Order categoryOrder category
Order typeOrder ty pe
The document type is used to differentiate between business transactions in the R/3 System. Orders are one category of business transaction. Orders are divided up according to order category , as it is possible to have different orders within the
different applications. The system predefines fixed order categories for each application. You have the option of individually defining order categories for each order type within an application. An order type is used to control different processes:
Number assignmentSetting default valuesUser-specified status managementUser-specific field control (not for production orders in Release 4.7)
Control of special functions (activating BDE, QM, LIS,... .) You define the settings for this in Customizing.
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Definitions in the Production Order
WhatWhat isis being producedbeing produced ??
WhenWhen isis it beingit beingproducedproduced ??
How much hasHow much h as toto bebeproducedproduced ??
For whom are we producingFor whom are we producing ??((costcost object)object)
Which resourcesWhich resources andand methodsmethodsare being usedare being used in thein the productionproduction ??
Which costs are incurred byWhich costs are incurred by th eth eproductionproduction ??
Products Ac ti vi ty
Planned ord er datesBasic order datesCalculated datesConfirmed dates
ReleaseStartFinal
Planned order quantityProduction order quantityConfirmed quantity
MaterialCost center
Order Asset
Material usageProd. resources/toolsChecks
Planned Ac tual
The production order is determined by a series of definitions for manufacturing a product.
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Production Orders and Organizational Structures
Organizational unitsOrganizational units
Production order
Shop floor control
Demand management
Requirements planning
Inventory management
Company
Controlling areas
Sales organizations
Company codes
Valuation areas
PlantsPlants
Storage location s/batches/special stocks
Purchasing organizations
Production orders generally relate to the organizational unit plant . The organizational units above a plant can be structured in various ways.
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Master Data for the Production Order
Required quantity and usage valueControl dataRequired quantity and usage valueControl data
BOM
Routing
MaterialMaterial
BOMBOM
Work center Work center
RoutingRouting
ProdProd .. resourcesresources //toolstools
Material usage (Mat. no., item cat., quantity)Storage location (proposal for withdrawal)
Operation default values Available capacity and formu la requ ir ements Activi ty type and for mula costs
OperationsStandard values
Procurement type E or XMRP, work schedule, acct. and costing data
Material status (MARA and MARC)
The material to be produced must have already been designated procurement type in house production(X,E).
The material status must be released for production on both a cross-plant level (MARA) and a plantlevel (MARC) .
At least one plant specific view (MRP and/or work scheduling) as well as financial accounting andcosting views must be maintained for the material.
You prepare BOMs as single level BOMs . A special selection procedure chooses the correct BOM. After you have prepared a routing, a special selection procedure chooses the correct one.
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ProductionProduction
Production operator Production scheduler
(supervisor)
ProductionpreparationProductionpreparation
Docu. &analysisDocu. &analysis
Industrialengineer
Salesplanning
Salesplanning
Designengineer
Plantreqmts
DetailedPlanning
Production planner Plant manager MRP controller
Production scheduler
Production operator Production scheduler
Plant manager Quality
inspector
Order-Related Production - Roles
Within the development of the SAP product " mySAP.com ", computer-supported work centers have been created along the entire process chain for order-related production.
Production order management touches on at least those roles shown on the slide. Individual roles are assigned different activities (tasks), authorizations and responsibilities that
correspond to the actual daily work carried out in practice.
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Production Order - Symbol Overview
Order header
Detail screen (operation , comp onent, PRT, ...)
Sequence overview
Component overview
Operation overview
Document overview
Status overview
Key
Collective order ov erview
Log
Trigger point overview
Change
Display
Save
Deletion
Schedule (order, collective order)
Cost
Check availabili ty (material, capacity, PRT)
Release (order, operation)
Enter long text (text editor)
Generate object (for example, order)
Execute program (function)
Update
The slide shows the most frequently used pushbuttons (symbols) in the production order. The symbols have been arranged on the individual production order screens in such a way that you can
always find the relevant symbol in the same place on the screen. Order functions are arranged on the left and navigation function s on the right . In the overviews of the operations, components and production resources/tools, the relevant pushbuttons
for the individual object have been arranged underneath the overview . Where it was considered appropriate, pushbuttons were placed directly next to a data field.
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Order type
LO215 - Commonly Used Abbreviations
Table T399XSPRO + SFC + Master Data + Order-TypeDependent Parameters
Order type parameters
Table T003OSPRO + SFC + Master Data + Order Types
PP-SFC
Scheduling parameters ofthe order type
Table TCX00_FASPRO + SFC + Operations + Scheduling + SchedulingParameters
Production Planning - Shop Floor ControlSAP + LO + PP + Shop Floor Control
Customizing Transaction SPROSAP + Tools + Accelerated SAP + Customizing +Edit Project
Task menu (SAP) Transaction sess ion_manager
During the LO215 course, the instructor may repeatedly use certain terms, tables and shortcuts . Theslide contains the most important terms and their menu paths.
The instructor will not always repeat these menu paths.
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Order data structureProduction order screens
Overview of order processing
Order Structure and Processing: Contents
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Order Structure and Processing: CourseObjectives
At the conclusion of th is un it you will be ableto :
Describe production order data structure
Describe the most important production orderscreens
Summarize the main functions of order processing
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Goods ReceiptGoods Receipt 1010
ConfirmationsConfirmations 99
Information SystemsInformation Systems
1212
SettlementSettlement ,, Archiv ing Archiv ingandand DeletionDeletion 1111
CollectiveCollective OrdersOrders 1414
Mass ProcessingMass Processingand Automationand Automation 1313
MaterialMaterial StagingStaging 77
33
Order Contro lOrder Contro l 88
PrintingPrintingOrder Order DocumentsDocuments 66
Order ReleaseOrder Release
55
Order Order CreationCreation //Order ChangeOrder Change 44
Overview Diagram (3)
IntroductionIntroduction 11
OverviewOverview 22
Order Order StructureStructure //ProcessingProcessing
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Elements of an Order
Order header Order header
OperationsOperations
Capacity spl itsCapacity spl its
MaterialMaterial componentscomponents
ProdProd .. resourcesresources //toolstools
Trigger PointsTrigger Points
ConfirmationsConfirmations
Order number
PlantProduction scheduler
Work center Control key
Standard values
Individual machineIndividual person
Settlement ru leSettlement ru le
Settlement profileSettlement receiver
Material number QuantityReqmts date
PRT number PRT category
Number
Functions
QuantitiesTimes
CostsCosts
Planned Actual
Document linksDocument links
Doc. number Doc. category
OperationOperation sequencessequences
Standard sequenceOther sequences
The order structure can be enhanced by adding certain elements. At least one operation is required. The system automatically creates this operation when missing. You have the choice of whether or not to assign material components, production resources / tools
and trigger points to the operation. You can create several (parallel) operation sequences. You can make a selection from several alternative sequences . Suboperations are permitted within an operation. Costs are determined at operation level and submitted at order header level only in the case of order-
related cost object controlling .
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Production Order - Header
1000767
General Assignment Goods receipt Control Dates/quantities Master data
Order typeOrder number PlantMaterial or activityQuantit ies dates
To RoutingTo BOMTo Costing
Entered by / Changed byPlants
Assign men tsMRP controller
Control of goods receipt
Movement typeSettlement rul eSettlement receiver Percentages
Deadline monitoringQuantity m onitoring
Product (activity) to bemanufactured with the order
ManualPlanned order
Definition Origin
Order Edit Goto Header Functions Environment
The segment of the order header describes the product that is to be manufactured with the productionorder (finished product, assembly, individual part).
There are a series of detail screens for the order header. The header text of a production order can either be the short text of the material master or the header
text of the routing that has been copied into the production order (with reference to this, see the switchin table T399X ).
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Production Order - Operation
1000767
Stand. values Ext. processing Interoperation times Standard value calc.
Operation 0010
Operation overview
Single step inOrder
ManualRouting
OperationSuboperation
Definition Origin Types General Data
Standard values
Ext. process ing
Interoperation timesStandard values calc.SplittingOverlapping
Operation dates
User field sQuantities/activitiesConfirmed dates
Order Edit Goto OperationFunctions Environment
GeneralData
This segment of the operation describes the individual work steps of the production order. There are a series of detail screens for an operation. These screens, in turn, incorporate further detail screens .
For example, you can branch from the component overview to screens for each material component. You have the option of inserting suboperations hierarchically with reference to an operation.
This enhances calculation and capacity planning .The operation control key of the sub-operation plays an important role in this.
Scheduling always occurs at operation level . The standard values of the suboperations can be cumulated on the corresponding operation when the
dimension and units of measurement are the same. It is not possible to assign material components or production resources / tools to sub-operations.
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Production Order - Material Components
1000767
Purch.data VarSzeltmDta Co-product Text item
Compon. 0010
Material number Material descriptionRequir ements qtyReqmts date
ReservationItem categoryBulk mat. indicator
Availab le quant ity
Issued quantityMissing parts quantity
Text editor
OriginDefinition
Materials required for anoperation or for manufacturinga product
Manual
BOMPlanned order
Order Edit Goto ComponentFunctions Environment
General data
In a production order, you can assign any number of material components to an operation. The segment for the material component describes the material required to carry out the individual
operations. There are a series of single screens for a material component.
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Production Order - Production Resources/Tools
Definition
1000767
General Quantities Dates
Item 0010
TypesOrigin
PRT number PRT control keyPlant
Requirements q ty
Usage valueFormulasUsage dates
Document (graphics)PRT text
Production resources/tools requiredto execute an operation Manual
Routing
MaterialEquipment(as of 3.0)DocumentOther Order Edit Goto PRTsFunctions Environment
In a production order, you can assign any number of production resources/tools to an operation. The segment for production resources/tools describes the required devices, tools, test equipment and so
on required for executing an individual operation. The production resources/tools category is essentially derived from the demands on a production
resource/tool and its relationship to a certain object (material, equipment and so on).
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Production Order - Documents
P-100
Order Processing Go to DocumentFunctions Environment
Doc. Data Additional Data Descriptions Object Links Original
Document
Document no.SubdocumentDocument version
Assignmt to oper ationOriginFormat
Object link
Original appl . file(s)
Storage data
Definition
Production resources/tools required
execute an o rder
Origin
Manual
Material Master Bill o f MaterialProd.Version
000 00
Originals
You can assign any number of documents to a production order. These are maintained in theDocument Management System (DMS).
The documents themselves are only linked to the production order and not saved in it. You can create links from documents to a production order manually or automatically . Documents can be drawings, texts, videos and so on. Application example: Product descriptions
Assembly instructions and diagramsInspection instructions and certificatesWork instructionsStorage and transportation regulationsSpare parts lists
Maintenance regulations
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1000767
Costs arising during theexecution of a production order
Aut omaticCosting
Definition Origin
Order Edit Goto Header Functions Environment
Production Order - Costs
OverheadOverhead costscostsCalculated in overhead structure
Production costsProduction costsIn-house production
Activi ty pr iceaccording to valuationvariant
Ext. processingPrice acc. to valuationvariant
MaterialMaterial costscostsStock materialPrice d eterminationaccording to valuationvariantNon-stock materialPrice from purch. info record
Process costsProcess costs Ass ig ned acc. to template
Itemization Cost categories Cost comp. structure
If order-related cost object controlling is used, each individual production order has a cost object(CO).
Order costs can be calculated manually or automatically .You define this by setting up the order-type dependent parameters accordingly in Customizing (tableT399X).
The CO object enables you to display different lists of costs for a production order. By choosing Goto + Costs in an order, you can find lists for the terms
Itemization (detailed overview of the individual costing items)Analysis (overview structured according to cost category)
Cost component structure (overview structured according to arithmetical cost components)
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Production Order - Settlement Rules
OperationsOperations
Material componentsMaterial components
Prod. resources/toolsProd. resources/tools
Costs PlannedTarget
Ac tual
Costs PlannedTarget
Actual
2050
100
Order header Order header
Definition
Material
Cost center
CO order
Asset
WBS element
Sales order and so on
Manual
Aut omatic
Receiver of order costs
Account assign ment categor ies
Origin
You control order settlement by way of settlement rules . The order can be settled proportionally to one or more receivers . Settlement rules are created manually or automatically (during order creation).
At the latest, they must be maintained before the goods receipts posting is carried out for the material to be produced.
You define the settings for order settlement in Customizing. If you use product-related cost object controlling , the settlement rules are contained in the product
cost collector and not in the production order .
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Processing a Production Order
11Order request
Order creation
Availabi litychecks
Print o rder
Material st aging
Order settlement
Archiv in g / deletin g
Goods receiptOrder release
Confirmations
2050
100Determine WIP
Calculate variances
Order processing
Machinereservation
22
33
44
55
66
7788
99
1010
1111
1212
1313
1414
Order header Order header
Operations
Materialcomponents
Prod. resources/tools
Costs PlannedTarget
Actual
The production order runs through a wide range of individual activities . WIP calculation, variance calculation and settlement are generally periodic operations for cost
object controlling that are processed in the background . You must define a series of settings for each individual stage if an order is to be processed successfully. CO Configuration includes a special feature that sets the prerequisites for WIP determination, variance
calculation and settlement.
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Order Structure and Processing: Summary
You have gained an overview of the data structureof a production order
You know the most important production orderscreens
The basic functions of production ordermanagement were shown in an example
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Exercise Data
Note:
There will not be sufficient time to work throughall the exercises during the course. The exercisesmarked Optional should be seen as supplementaryexamples that can be used, as required and time
permitting, during the course. Attendees can alsouse these exercises after the course, to consolidatewhat they have learned.
Explanation of the Symbols in the Exercises and Solutions
Exercises
Solutions
Course Objectives
Business scenario
Tips & Tricks
Warning or caution
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Data in the exercises
Type of data Data in training system(ID3, client 400)
Data in the IDES system (ID3, client 800)
Group no. xx (01....20)
User master records LO215-xx passwordFERT
Client 400 (401, 402) as pertraining room
Customizing project 200 200
Company code 1000 1000
Business area 1000 1000
Purchasingorganization
1000 1000
Sales organization 1000 1000
Distribution channel 10 Final customer sale 10 Final customer saleDivision 00 Multiple division 00 Multiple division
Sector M Mechanicalengineering
M Mechanicalengineering
Personnel area 1000 1000
Personnel subarea
Chart of accounts INT INT
Controlling area 1000 1000
Cost center hierarchy H1 H1
Cost center nodes 4200 4200
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Cost centers 4210, 4220, 4230 4210, 4220, 4230
Activity types 1410 Machine time
1420 Setup time1430 Personnel time
1410 Machine time
1420 Setup time1430 Personnel time
Factory calendar 01 01
Plants 1000 (Normal)
1100 (special structures)
1000 (Normal)
1100 (special structures)
MRP controllers 100, 101 Demo
001 to 002 Participants
099 Instructor
100, 101 Demo
Capacity planner 100, 101 Demo
001 to 002 Participants
099 Instructor
100, 101 Demo
Production scheduler 100, 101 Demo
001 to 002 Participants
099 Instructor
100, 101 Demo
Production scheduling profile
0000001 Normal
0000002 automatic
0000001 Normal
0000002 automatic
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Normal flow
Collective order
Config.var. scn. 1
Config.var. scn. 2
Config.var. scn. 3Changemanagement
Normal flow
Rework
Automat.Procedure
Limited no. ofVariants
W/o BOM and plan
Select. BOM/plan
Op. consequences
Co-products
Mat. components
Mat. staging
Availability
Discontinued parts
Cross-plant
Split valuation
Batch production
Ext. Proc. / proc.
Serial numbers
Repetitive /order- based production
Stockdetermination
P-100
P-400
P-500
P-501
P-502P-600
100-300
100-301
T-A
T-V1, V2
T-MAN
T-SEL
T-OS
T-COP
T-MC
T-MS
T-MA
T-MD
T-PDP
T-MV
T-BCH
T-EX
T-SN
T-REP
T-STOCK
P-100
P-400
P-500
P-501
P-502P-600
100-300
100-301
T-A
T-V1, V2
T-MAN
T-SEL
T-OS
T-COP
T-MC
T-MS
T-MA
T-MD
T-PDP
T-MV
T-BCH
T-EX
T-SN
T-REP
T-STOCK
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Bills of material T-F1xx
P-100P-400
P-500
P-501
P-502
P-600
T-A
T-V1, V2
T-SEL
T-OS
T-COP
T-MC
T-MS
T-MA
T-MD
T-PDP
T-MV
T-BCH
T-EX
T-SN
T-REP
P-100P-400
P-500
P-501
P-502
P-600
T-A
T-V1, V2
T-SEL
T-OS
T-COP
T-MC
T-MS
T-MA
T-MD
T-PDP
T-MV
T-BCH
T-EX
T-SN
T-REP
Routings T-F1xx
P-100
P-400
P-500
P-100
P-400
P-500
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P-501
P-502
P-600
T-A
T-V1, V2T-SEL
T-OS
T-COP
T-MC
T-MS
T-MA
T-MD
T-PDP
T-MV
T-BCH
T-EX
T-SN
T-REP
50000003 standard tasklist
P-501
P-502
P-600
T-A
T-V1, V2T-SEL
T-OS
T-COP
T-MC
T-MS
T-MA
T-MD
T-PDP
T-MV
T-BCH
T-EX
T-SN
T-REP
50000003 standard tasklist
WM storage bin PROD-1310 PROD-1310
Standard trigger
point
T-NACHARB T-NACHARB
Order types PP01 Demo andexercise
PP03 Demo andexercise
PP04 Demo and
PP01 Demo
PP03 Demo
PP04 Demo
PP06 Demo
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PP Exercise Material - BOM T-F1xx
T-F1xx (FERT, P-100)(1000, 0, _ )
1 81
T-T1xx(ROH, 100-110)(1000, 1000, 2 )
T-T2xx(ROH, 100-120)(1000, 1000, 2 )
T-T3xx(ROH, 100-130)(1000, 1000, 2 )
1
T-T4xx(ROH, 100-310)(1000, 1000, 2 )
1
T-B1xx (HALB, 100-100)(1000, 10, 2 )
1
T-B2xx (HALB, 100-200)(1000, 10, 2 ) (1100, 10, 2 )
1
T-B3xx (HALB, 100-300)(1000, 0, _ )
1
T-B4xx (HALB, 100-400)(1000, 10, 2 )
T-T0xx(ROH, 100-210)(1000, 1000, 2 )
1
(1100, 1000, 2 )
Key: (Material, IDES template)
(Plant, stock qty, sec. reqmts ind.))
Item 00 10 0020 0030 0040
1
T-T5xx(ROH, 100-410)(1000, 1000, 2 )
os. 00 10 0020 0030 0010 0010 0010
1
Dokument T-F1xx DRW, 000, 00
0050
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PP Exercise Materials - Routings
not a ssigned
10TP-Lxx( 1310 )
0010T-Mxx( 1310 )
0030 T-Lxx( 1906 )
0020T-Vxx( 1320 )
0040 T-Exx( 1904 )
0050T-Fxx( 1721 )
0060 T-Pxx( 1721 )
T-VHhierarchy:
T-V
Assignm ent tosta t . work center
a nd hierarc hy
T-EHhierarchy:
T-E
T-F1xx(FERT, P-100)(1000, 0, _ )
T-F2xx(FERT, P-100)(1000, 0, _ )
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Order Structure and Order Processing Exercises
Unit: Order Structure and Order Processing
Topic: Order Structure and Order Processing(LO215 Exercise 1)
Structure (data and contents) of a production order
In your capacity as production manager, production scheduler,supervisor or operator, you work with production orders all thetime. In this exercise, you will become familiar with the structureof a production order.
1-1 Display the production order no. _______________ .
Path: S000 LO PP SFC ORDER DISPLAY
1-2 Display the individual data segments, screens and their data fields in the followingorder:
Note any questions you may have about the meaning of the data fields.
If the meaning of any of the data fields is not clear, ask the instructor.
1-2-1 Order header screens
Path: GOTO HEADER
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Select the corresponding tab index for the respective screen.
GeneralAssignmentGoods receipt
ControlDates/quantitiesMaster dataLong textSettlement rule
Path: HEADER SETTLEMENT RULE
1-2-2 Overview of the operation sequences
Path: GOTO OVERVIEWS SEQUENCES
1-2-3 Operation sequence details
Path: SEQUENCE DETAILS
1-2-4 Operation overview
Path: GOTO OVERVIEWS OPERATIONS
1-2-5 Operation screens (select operation " 0010" )
Path: OPERATION OPERATION DETAILS
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Select the corresponding tab index for the respective screen.
GeneralStandard valuesExternal processingInteroperation times
Standard value calculationSplittingOverlapDatesUser fieldsSuboperation/datesQuantities/activitiesConfirmed datesQualificationLong text
1-2-6 Material components - Overview
Path: GOTO OVERVIEWS COMPONENTS
1-2-7 Material component screens (select component " 0010" or "0070" )
Path: COMPONENT COMPONENT DETAILS
Select the corresponding tab index for the respective screen.
Item 0010 General Data
Item 0070 VarSzeltmDta
1-2-8 Overview of production resources/tools for operation "0050"
Path: Go to the operation overview and select operation "0050".
In the menu bar at the bottom of the screen, select the PRT pushbutton(Production resources/tools)
1-2-9 Screens for the production resources/tools (select production resource/tool"0020" )
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Path: PRODUCTION RESOURCE/TOOL PRODUCTION RESOURCE/TOOL DETAILSHILFSMITTEL
Select the corresponding tab index for the respective screen.
Item 0020 GeneralQuantitiesDates
1-2-10 Document overview
Path: GOTO OVERVIEWS DOCUMENTS
1-2-11 Display of the document information record (select the first document)
Path: DOCUMENT DISPLAY DOCUMENT INFORMATION RECORD
Select the corresponding tab index for the respective screen.
Document data
Additional data
DescriptionsObject links
Original
1-2-12 Display of the original document (display both originals from the documentoverview for the order)
Path: DOCUMENT DISPLAY ORIGINAL DOCUMENT
1-2-13 Costs
Itemization
Analysis (Cost categories)
Cost comp. structure (Cost component
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Order Structure and Order Processing Solutions
Unit: Order Structure and Order Processing
Topic: Order Structure and Order Processing(LO215 Exercise 1)
No answers are required for this exercise.
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Order Creation/Order Change: Contents
Function procedure "Creating an order" Automatic follow-on post ingsCreation variants
NormalWith production versionNo reference to material (any activity)Copy from order Related to sales order
With variant configuration
Bill of material and task list selectionConverting planned ordersReading master dataOperation sequences in an order
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At the conclusion of th is un it you will be ableto :
Order Creation/Changing Orders: CourseObjectives
Define the basic features and variants for creating production ordersDescribe subsequent functions in order creationDescribe the process of routing and BOMselection when creating an order Define how master data is read intoexisting ordersDescribe how to create and convertplanned orders
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Goods ReceiptGoods Receipt 1010
ConfirmationsConfirmations 99
Information SystemsInformation Systems
1212
SettlementSettlement ,, Archiv ing Archiv ingandand DeletionDeletion 1111
CollectiveCollective OrdersOrders 1414
Mass ProcessingMass Processingand Automationand Automation 1313
MaterialMaterial StagingStaging 77
Order Order StructureStructure //ProcessingProcessing 33
Order Contro lOrder Contro l 88
PrintingPrintingOrder Order DocumentsDocuments 66
Order ReleaseOrder Release
55
44
IntroductionIntroduction 11
Order Order CreationCreation //Order ChangeOrder Change
OverviewOverview 22
Overview Diagram (4)
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Creating Production Orders
FridayJuly
27 1992
TuesdayDecember
18 1992
ManualManual Requirements planningRequirements planning Aut omatic Aut omatic
Specify order type
Define order item
Copy routing
Copy bill of material
Lead time scheduli ng
Optional (Customizing)
Availabi lity check
Add, change
Save producti on order
Various functions (1)(1)
The production order can be generated automatically (confirmation, sales order) or manually (directly) by converting it from a planned order .
A start / finish date is entered for the order item (product) according to the scheduling type (forwards or backwards) .
Lead time scheduling is executed automatically. It calculates the start / finish dates of the order and thedetailed dates and capacity requirements of the operations.
You also have the option of carrying out an availability check (specifiable in Customizing). You can determine the planned costs when saving the order (specifiable in Customizing). ((11 )) Other functions that can be executed automatically are:
Batch creation, determination, order classification, serial number assignment, document integration.
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Automat ic Postings
MaterialMaterial reservationsreservations
Purchase requisitionsPurchase requisitions
CostsCosts (CO object)(CO object)
Capacity r equirementsCapacity r equirements
TransportTransport requirementsrequirements
Inspection l otsInspection l ots
PRTPRT requirementsrequirements
Inventory management
Purchasing
Controlling
Capacity planning
Warehouse management
Quality management
PRT management
When you create a production order, a series of additional posting procedures occur at the time ofposting (the data is already formatted online).These automatically generate the required data for stored parts of the system .
Material reservations are generated for all warehouse components. You can choose whether thesereservations are to be immediately relevant to MRP or not until the time of release (indicator in theorder-type dependent parameters T399X)
Purchase requisitions are created for non-warehouse components and externally processed operations. Costs are determined when you save . Transport requirements are generated when the operation is released . PRT requirements are only generated internally. At the present time, however, there is no
requirements planning for PRTs which works with these records.
Transaction CF21 (using PRT in orders) is available for evaluating PRT requirements in productionorders.
Missing parts records are written for missing parts.
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Creation Variants 1
2050
100
Activi ty
Directly (manually)From planned order
Copy from order
For sales order
From SD (assembly order)
From confirmation(rework)
As co ll ect ive order
With variant configuration
Order header Order header
Operations
Material components
Prod. resources/tools
PlannedTarget
Actual
Costs
With reference to material
Without reference to material
There are numerous possibilities for creating production orders.
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Creation Variants 2
Order
Order
Planned
Planned Order
Material BOM
Order Planned order
Planned
Create without routing andbill of material
Create with routings
Create with r outingand b il l of mater ial
Create with plann ed order
Operations, material components and production resources / tools are normally copied from the routing and BOM .
You can also input such information manually . The BOM is not reread when you convert a planned order. If you do not specify otherwise in a routing, the system automatically assigns the BOM components to
the first operation .
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Own scheduling for planned ordersTo the dayCalculated basic dates Basic start date
Basic f inish dateCreation date
Base in-house production time or replenishment lead time Advantageous f or per forman ceNo capacity requirements are determined
UsedTo the second
Starts from basic dates Requirem ents planningManual
Determined pr oduction dates (scheduled dates)Start d ateFinish dateRelease date
Base operationsDetermined capacity requirements
Material requirements planning
Lead time scheduling
Periods
Order header Order header
Operations
Materialcomponents
Prod.resources/tools
Costs PlannedTarget
Actual20
50100
for orders and routings
Scheduling in Production Planning
Production planning has two scheduling methods that are used differently and have different results: Scheduling of planned orders in material requirements planning (calculates the basic dates only) Lead time scheduling (starts from the basic dates and calculates the production dates)
Only lead time scheduling calculates operation-related dates and capacity requirements. Lead time scheduling is the basis for
Order scheduling Routing scheduling Scheduling in applications PS, PM, PI
In addition, lead time scheduling can be activated in material requirements planning in order todetermine capacity requirements for planned orders.
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Number Assignment for a Production Order
. . . .
1000000100000019999991999999
2000000200000029999992999999
3000000300000039999993999999
PP02PP02PI02PI02..........
XX
PP01PP01IDESIDESPP06PP06........
PI01PI01............
Number rangeNumber range objectobject for for anan order order ((generalgeneral ))
Range fromto
Assignment in ternalexternal(x)
Assignment of th eorder types(element)
Number range -Group 1
Number range -Group 2
Number range -Group 3
Order numbers are assigned according to order typ e. Numbers can be assigned either externally or internally . The order number can be composed of a maximum of 12 characters . Order numbers can be defined independent of company codes, plants and other organizational
structures. A number range group must be specified for each predefined number range. You can create an
unlimited amount of number range groups. The order categories can be assigned to any of the number range groups. The system does not allow
multiple assignment. The current status of the internal number assignment can be changed manually provided that the
sequences are taken into account. You maintain the number range in Customizing.
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Task List Selection Criteria
Selection type (T399X) " With / without routing""Routing required / optional""Manual / automatic selection""With / without ref. operation set""P" (Production)"N" (Normal) " S" (Standard)
Task list usageTask list type
Task list selection IDUsage
Material no.Plant
" Alternative selection" indicator (MRP screen 4)
Production version
GroupGroup counter StatusValidityLot-size rangeDeletion flag = = "X"
"Order quantity""Basic start/finish date""Released"
(in reference operation sets)
CustomizingCustomizing
Routing
Material
A
"Production version" indicator (T399X)
You define the routing selection options in Customizing . The most important tables are :
T399X order-type dependent parameters andTCA43 automatic selection
You can determine whether a routing is necessary or not (selection type). All criteria are always checked and a routing is only selected if all criteria are fulfilled. Determining which validity the routing should be selected with is dependent on the setting in table
T399D ( Customizing Requirements Planning) .
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BOM
Stage
0
1
2. . .
. . .
20
50100
HEADERHEADER
ITEMITEM
ITEM
PumpP-100
Pre-assembled casing
100-100
Pre-assembled shaft
100-300
Casing
100-110
Support base
100-700
Shaft
100-301
Order header Order header
Operations
Material components
Prod. resources/tools
PlannedTarget
Actual
Costs
BOMs contain the material structure and required quantities of the individual components for a product. The required quantities are not dependent on the order.
BOM data is copied to the production order . Subsequent changes you make to the BOM do not takeeffect on orders that already exist.
When you create an order, a BOM is chosen on the basis of the corresponding selection criteria . The BOM is exploded on one level . An exception to this is multi-level BOM explosion for so-called phantom assemblies . Subitems are not copied to the order.
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Bill of Material Selection - Procedure
BOM alternativealternative (T415A)
Addi tion alcriteria
= Blank
=
No
= 2
=Yes
= 1
Sel. ID
Mat. master Indicator " Alternative
selection"
PP parameters for order type (T399X)
"BOM usage"
BOM usage(TC04)
BOM selection bylot size
BOM selection bydate
Selection b ydate permitted ?
BOM selection byPV
Selection b yPV permitted?= 3
Mandatory BOMselection by PV
Key:PV = Productionversion
BOM usagepriorities (TCS41)
PP parameters for order type (T399X)
"ProdVersion" indicator
BOMBOM
BOM
= Yes
= No
During automatic selection, the alternative selection indicator in the material master (MRP screen 4)determines the selection procedure.
Note the following special features: IND = Blank
The system takes the BOM usage that is defined for each order type from table T399X , enters tableTC04 with this and takes a selection ID from this table. The system uses this selection ID andsearches the sequence of priorities contained in table TCS41 for the first available BOM that fulfillsthe lot size and BOM usage criteria .
IND = 1Selection according to date requires that an entry is maintained in Customizing for the material(T415A a lternative selection multiple BOM).
IND = 2The system searches the material master for production versions that fit the lot size .If only one exists, then its BOM is checked against all criteria (also those contained in TCS41!). Ifthere are more than one , table T399X decides ( production version indicator) whether the user(dialog box) or the system (automatic) determines which production version is to be selected. If,despite this, no valid BOM is found, the system does not stop .The system carries on searching using the procedure for when the indicator is "blank".
IND = 3Same as for value = 2 . If no valid BOM is found in this case, the system stops searching!The production order has no components.
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Selection according to production version presupposes that valid production versions have beenmaintained in the material master.
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Item Categories in the Production Order
2050
100
Reservation
Purchaserequisition
Find objectfor class
Order header Order header
Operations
Material components
Prod. resources/tools
PlannedTarget
Actual
Costs
Stock item
Variable-size item
Non-stock item
Text item
Class i tem
Item categories control the data scope and functions of a material component. Typical examples are:
Stock item Non-stock itemVariable-size itemText itemClass item
You cannot make alterations to item categories once they have been set. Follow-on documents are generated with the production order according to item category. Components with the item category "non-stock item" automatically generate a purchase requisition.
This can be displayed for an item via a further screen. The class item stands for a wide variety of different materials. When you enter the command "find
object function for class", the system can specify the class item in a particular stock item. The "document item" is transferred to the document list of the production order (document link)
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Reservation
1
Material A
Reservation
Header
ItemItem
ItemItem
ItemItem MaterialPlant / Storage location
Reqmts dateMovement allowedCommitted qty
Base date
Check calendar
Assign ment
The system generates material reservations for all material components of a production order of the type "stock material" .
Reservations are taken into account when determining the conditions for material requirements planning. Reservations are also taken into account when creating goods movements for components of the production order.
A reservation item applies to a plant or a plant's storage location . A requirements date is defined by the order for each item. You can control whether goods movements
are allowed for the reservation item by means of an indicator. The reservations for material components of the production order are assigned to this production order. You can compile lists of reservations for the material or account assignment (production order).
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Material Assignment
Item 20
Item 10
Op.30
Op.20
Op.10
MaterialB
Material A
Routing BOM
You can assign material components to operations both when managing BOMs and routings . The assignment of material components to operations is copied to the production order. If no assignments are maintained, then the system automatically assigns the BOM material
components to the leading operation . When you display the material components overview , you can assign material components to
individual operations and display material components. The material components list can be sorted andfiltered according to various criteria in order to enhance this overview.
Other functions include:Assigning, reassigning and deleting material assignments. Navigating between operations
You are able to reassign materials up to the point of order release .
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Assignment of Production Resources / Tools
Production order
Op.10
Op.20
Op.30
PRT1
PRT2
You can assign production resources/tools to every operation in a production order. Production resource/tool assignments are copied from the routing to the production order.
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Document Integration in Production Orders
Production order
Routing
BOM
DMSMaterial
B
Master Data Document ManagementSystem (DMS)
Material item 10
Document item 20
Document item 30
Operation 10
Operation 20
Document 1
Document 2
Document 3
Prod. res./tools Production res/tools
Order item
Overview of documents in PrO
Document 4
Document 5
Document link 4
Document link 5
Document link 1
Material item 10
Operation 10
Operation 20
Document link 2
Document 6
Fri
Fri
Fri
Fri
You can assign any number of documents to a production order. These are maintained in theDocument Management System (DMS).
Documents can be drawings, texts, videos and so on. The documents themselves are only linked to the production order and not saved in it. You can create links from documents to a production order manually or automatically . Automatic linking of documents takes place during order creation or release. The document items are
copied from the BOM, the production version or from the document link to the material master ofthe product to be manufactured.(This must be activated in the production scheduling profile - Customizing for Shop Floor Control)
Document links in the production order created in this way can be displayed, changed, deleted, printed(separate list), archived and displayed in the product structure browser .
Original document s cannot be printed out. All document types that you use must be permitted for object PORDER (production order), work with
status management and must be released. (See Customizing for the Document Management System). Examples, see above:
Document 1 Link copied from material masterDocument 2 Link created manuallyDocument 3 No link to production orderDocument 4 and 5 Link created from BOM itemDocument 6 does not appear in the document overview of the production order
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Operation Sequences in a Production Order
Product AOrder header
Sequence typesStandardStandard
sequencesequence 00000000 Alternative Al ternative
sequencesequence 00010001
ParallelParallel sequencesequence00020002
Op. 70
Op. 80
Op. 10
Op. 20
Op. 30
Op. 40
Op. 50
Op. 60
Op. 10
Op. 15
Op. 20
Op. 70
Op. 80
Op. 90..
Alternative and parallel operation sequences are possible in production orders. The alternative sequence gives you the option of choosing alternative operations for a sequence of
operations. The parallel sequence enables you to process operations parallel to and independent of other operations. You can copy both sequence types in an order from a routing (via Customizing).
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Alternat ive Sequences
> 20
25
< 30
Operation 10
Operation 20
Operation 30
Operation 40Operation 50
> 10
15
20
25
< 30
Alternative Alternativesequencesequence 00020002
StandardStandard sequencesequence00000000
Alternative Alternativesequencesequence 00010001
Alternative sequences are linked to the standard sequence. An alternative sequence can be created automatically when you create a production order or read the
master data. You can use the " exchange sequences" function to replace alternative sequences with a different
sequence . This exchange is possible as long as certain functions have not yet been executed .
For example, material withdrawals, confirmations, purchase orders . A switch is only possible if:
The standard sequence has branch and return operationsThe operation numbers are within the standard sequence rangeThere is no overlap with other alternative sequences.
Application: Changed work procedures with different lot sizes and capacity bottlenecks(external processing).
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Parallel Sequences
20 25 30
30
20 30
40 50 60
45 55
IIIII
IIIIIIIII
IIIIIIIII= Floats
IIIIIIIII
Parallel sequence 1
Parallel sequence 2
Parallel sequence 3
Operation 10 Operation 20
Alternative and parallel operation sequences are possible in production orders. The parallel sequence enables you to process operations parallel to and independent of other operations. You can copy both sequence types in an order from a routing (via Customizing). Parallel sequences are linked to the standard sequence through predecessor / successor
relationships . Parallel sequences are a special form of overlapping operations. Parallel sequences create network-like structures. Order scheduling inserts operation floats according to the alignment key specifications. Applications:
In mechanical engineering for assemblies involving the production of individual components, inspection processes, and preparatory and closing operations. In the chemical industry for analysis processes that
are carried out in parallel to the production process.
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Read Master Data
2050
100
Routing 2
BOM 1
BOM 2
Routing 1
Material components
Order header Order header
Operations
Prod. resources/tools
PlannedTarget
Actual
Costs
You can use the function "Read PP master data" to switch the originally copied routing 1 and / orBOM 1 with a different routing and / or BOM alternative 2 .
This exchange is possible as long as certain functions have not yet been executed .For example, material withdrawals, confirmations, purchase orders .
Assignments of components (BOMs) and production resources/tools are retained, provided that thecorresponding operation still exists.
This function can also be used for collective orders (refer to the "Collective Orders" unit)
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Order Change Management(OCM)
Aims of change management for production ordersProvision of a system-supported tool for automated change of productionorders which are already being used in the production process.
The changes concerned can be triggered by changes in sales orders and/or master data
When are the OCM tools needed?Production orders are already being used in the production process and havebeen worked on
Customers change their order
Engineering or technological changes are necessaryMass orders are affected by changes (for example, collective orders)
Who needs the OCM tools?Sales-order-related production, make-to-order production
12
9
6
3
11 1
7 58 4
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If you wish to change orders already being used in production and the options provided by the "ReadPP master data" function do not suffice, you can use Order Change Management for productionorders (OCM) (as of Release 4.5).
The R/3 change management function enables the user to make changes that are coordinatedthroughout the order process, in terms of content and dates , to one or more objects (product masterdata and documents from business transactions currently in process).
Change management differentiates between:ECH = Engineering Change Management OCM = Order
Change Management ECH concentrates on the preparation and execution of changes to product master data. OCM concentrates on the exection of changes to production orders that are already being used in the
production process (and on finding planned orders or purchase orders that are affected by thesechanges).
The changes in OCM are based on changes from the area of product master data (ECH), as well ascertain changes from sales orders (SD).
You cannot carry out automatic unchecked changes to production orders that are currently being usedin the production process (for example, material consumption has been posted, order is partiallyconfirmed,...). This is why the R/3 system provides functions for the controlled change of orders.
Change management for production orders (OCM) is dealt with in detail in course LO980 .
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Order Creation with Planned Orders
Inspection l otInspection l ot
Planned order Planned order
RoutingRouting
Production order Production order
Order item Material components
Inspection data Operations PRT
Material number (Product)Requirements qtyReqmts date
Material number (component)Requirements qty
Inspection characteristicsTest values/characteristics
Op number Work center Control keyStandard values
PRT number Requirements qtyControl key
Planned orders are created via Material requirements planning (MRP ). Creating production orders from planned orders is the most important function of the whole PP
application. When you create a production order from a planned order, the system automatically supplies the production order data .
When an inspection lot is generated, the inspection data is copied from the routing but not written tothe production order.
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Material Requirements Planning (MRP)
MRP area: Plant
Material A
Planning unit Planning run types Processingkey
NEUPL
NETCH
NETPLNet change planningin the short-termplanning horizon
Net change planning
Regenerative planning
Material requirements planning is executed at the level of the MRP area (plant, warehouse, ...). Regenerative planning means that you plan all materials from the planning file. Net change planning means that you can only plan materials which are already entered in the
planning file and have therefore undergone a change relevant to MRP. Planning file entries can be generated either automatically or manually. Net change planning in the short-term planning horizon means that you can only plan materials that
have already undergone a change relevant to MRP within a restricted planning horizon . You can onlygenerate order proposals within the planning horizon.
Planning can either be carried out online or in the background . Material requirements planning (MRP) is dealt with in detail in course LO210 .
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Planned Order Structure
1000767
Header Assignment Master Data
Plnd order Processing Goto Extras
Material A
Requir ed material- Quantity- Requirements date
Items
Order typeQuantityDates
Detailed sched.Components
Capacity r eqmts- Operation- Work center - Reqmts date
PeriodsPeriodst
Capacity r eq. records
R / 3 R / 3 R / 3 R / 3 R / 3 R / 3 R /
3 R / 3 R / 3 R / 3 R / 3 R / 3 R / 3 R / 3 R / 3 R / 3 R / 3 R / 3 R / 3 R / 3
Planned receipt of the net requirements calculation for requirements coverage. Requirements transfer object for the dependent requirements. It can be used as a pegged requirement for capacity planning. It provides a data source for the production order.
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Multi-Level Materials Planning
PlannedPlanned --SalesSales --
PlannedPlannedindependentindependentrequirementsrequirements
PLANNED ORDER
PLANNED ORDER
PLANNED ORDER
Dependent requirementsDependent requirements
Dependent requirementsDependent requirements
E1E1
B1B1 B2
R1R1 R2R2 R3R3
Requirements planning covers a whole product structure. It runs in the following steps for eachmaterial. Checking the requirements coverage. Generating the planned order. Determining the dependent requirements. Entering the components into the planning file.
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MRP List
Header
Net planning
Single item planning
Storage location planning
Material
MRP parameters
- Items
- Items
- Items
Planning result
ContentsContents
Purchase requisitions
Planned orders
MRP list
An important result of material requirements planning is the MRP list . An MRP list is created for each MRP related material . Current stock and requirement situations are displayed as of the last planning run . The MRP list is subdivided according to different planning segments . Changes made between two planning runs are not displayed. Error messages are copied to a log.
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Current Stock/Requirements list
Production orders
Header
Net planning
Single item planning
Storage location planning
Material
MRP parameters
- Items
- Items
- Items
Stock/reqmts list
Purchase requisitionsPurchase ordersPlanned ordersSales ordersReservationsWarehouse stock
ContentsContents
MaterialMaterial
A further result of material requirements planning is the current stock / requirements list . This list displays the current and therefore up-to-the-minute stock / requirements situation . You can generate the list dynamically by directly reading the MRP elements. From this list, individual planned orders can be converted to production orders .
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Collective Conversion - Time-Oriented
Operations
Materialcomponents
Prod. resources/tools
Costs PlannedTarget
Actual
Purchaserequisition
Planned o rders
PD
PS
PO
PD
PS
PO
t
x Days later
Today
x Days earlier
Production orders
Opening period
Reqmtsplanning
Order header Order header
2010050
You can convert planned orders online either individually , collectively, completely or partially . You can convert planned orders in the background using the program PPBICO40 . Planned orders consist of a planned order start date (PS), a planned order finish date (PL) and a planned
order opening date (PE). When the planned order opening date is reached, you should convert the planned order into a production order or a purchase requisition.
When you convert a planned order into a production order, the planned order is deleted . The system reassigns the dependent requirements (material components) and any existing capacity
requirements to the newly created production order. By changing an indicator, the dependent requirements can then be turned into a reservation . When a planned order is only partially converted , it remains intact and is fixed . You can perform a collective conversion that is dependent on the outcome of a material availability
check (analogous to the order release).
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Converting Planned Orders - Time Frame
R1R1 B1
E1E1R2R2
R3R3
B2
t
Total lead time
Opening periodOpening period ((fromfrom -- to)to)
CurrentCurrent datedate
The MRP controller uses the "collective conversion" function to convert the planned orders of a product structure falling within a set time period.
In the framework of an entire product structure , the system will only convert those planned orderswhose planned order opening dates are within a defined opening period .
You can predefine the size of the opening period with reference to the current date in User Parameters(AEV, AEB) .
This procedure is particularly suited to deterministic make-to-stock production.
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Collective Conversion - Structure-Oriented
Prod. order 2
Prod. order 1
Preq
Prod. order 4
Prod. order 3
As an alternative to time-related collective conversion, the order progress report provides the "Convert planned orders" function for structure-related conversion .
An order progress report is available in Release 4.5. It enables you to clearly chart the progress of all business transactions (in-house production and external procurement) that are required when carryingout a sales order or project, and to process them.
Using this report, you can convert planned orders into production orders or purchase requisitions with the order structure in front of you.
This procedure is particularly suited to make-to-order production. Refer also to the Information Systems unit .
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APO as a Planning Tool
APO APO
Global ATP
Global ATP
DistributionDistribution
SAP BW
Historicaldata
Keyfigures
ExternalData
(for example,ITEM)
SAP BW
Historicaldata
Keyfigures
ExternalData
(for example,ITEM)
Demand planningDemand planning
Productionplanning anddetailedscheduling
SupplyNetworkPlanning
SupplyNetworkPlanning
Supply Chain CockpitR/3R/3
Sales anddistribution(sales orders)
Shop floor control
(prod. orders)
Inventorymanagement
Instead of R/3 requirements planning (MRP), you can use the new SAP product: Advanced Plannerand Optimizer (APO) . This product is one of the SAP New Dimension products.
APO enables a general, comprehensive portrayal, planning and monitoring of all processes in thelogistics chain, right down to a detailed level .
Open standard interfaces permit seamless integration of SAP Systems (highly-integrated solution forR/3), old systems and systems from external providers.
LiveCache , an SAP technology for processing data in the memory , gives APO its high performancelevel.
APO is an absolute planning machine . Inventory management, sales order creation and order execution and control (Manufacturing Execution)
are carried out outside of APO, for example in the R/3 System. Orders (planned, production or process) can be created and changed as the result of planning with APO. APO and R/3 are connected by the APO Core Interface (CIF) Data is kept consistent on both sides (APO and R/3). Planning with APO is dealt with in detail in courses AP010 to AP230 .
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Order Creation/Order Change Exercises
Unit: Order Creation /Order Change
Topic: Creating an order without basic data(LO215 Exercise 2)
Learn about the dialog for creating and changing a productionorder.
As production manager, production scheduler or supervisor, fromtime to time you must create production orders for which there isno master data (routing, BOM).This is particularly the case if production has to carry outunplanned work, special requests and other tasks.In this exercise, you will become familiar with the dialog forcreating or changing a production order.
1-1 Create an order using the following data:
Material T-MAN
Production plant 1000 Order type PP01
Total amount 10 piece
Basic finish date Any
Scheduling type Backwards
Path: S000 LO PP SFC ORDER CREATE
WITH MATERIAL
A dialog box appears: Routing Selection T-MAN
React to the system message: "No routing found" with
GENERATE OPERATION
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Machine time 10 pieces per 30 mins
Labor time 10 pieces per 60 mins
Path: S000 LO PP SFC ORDER CHANGE
1-6 Add material components "T-T1##" and "T-T2##" to operation "0010" in any quantity .
Use item category "L" for both.
Path: Go to the operation overview and select
operation "0010". In the menu bar at the bottom of the screen, select the COMPONENTS pushbutton
1-7 To operation "0020" , add the production resource/tool "PP-FHMM" . with anyquantity .
Path: Go to the operation overview and select
operation "0020".
In the menu bar at the bottom of the screen, select the PRT pushbutton
(production resources/tools)
A dialog box appears: PRT New Entries
Note that this production/resource tool has a materialmaster .
The window is set up accordingly. If you want to add otherPRT categories, you must select the pushbutton at the
bottom.
1-8 Execute a document link, by linking the order with document T-D##.
Document no. T-D##
Document type DRW
Subdocument 000
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Document version 00
Assign the document to operation 0010 .
Path: Go to the document overviewGOTO OVERVIEWS DOCUMENTS
1 -9 Check the operation overview.
1-10 Carry out order costing (determine costs).
Path: FUNCTIONS COST
1-11 Display the costing result.
Path: GOTO -> COSTS -> ITEMIZATION
1-12 Save the order.
Path: ORDER SAVE
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Order Creation/Order Change Exercises
Unit: Order Creation /
Order ChangeTopic: Creating an Order with Basic Data
(LO215 Exercise 3)
Routing and BOM selection
Production versions in a production order
Reading master data
As production manager, production scheduler or supervisor, as arule, you create production orders on the basis of master data(routings, BOMs), which has been created and is maintained inthe areas of engineering and work scheduling in your company.This is particularly the case when the production of materials andactivities is of a repetitive nature.In this exercise you become acquainted with the way in which theSAP System searches for and selects the master data that is validfor a production order.
2-1 Create an order using the following data:
Material T-F1##
Production plant 1000
Order type PP01
Total amount 1 piece
Basic finish date Any
Scheduling type Backwards
Path: S000 LO PP SHOP FLOOR CONTROL ORDERCREATE WITH MATERIAL
2-2 What is the validity date of the BOM and the routing in the production order?
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