LO305 Basic Data for process manufacturing

LO305 Basic Data for Process ManufacturingLO305

Release 630 29.08.2003

LO305 Basic Data for Process Manufacturing...............................................................................................................0-1

Copyright....................................................................................................................................................................0-2

Process Industry (PP - PI)......................................................................................................................................0-3

Prerequisites...........................................................................................................................................................0-4

Target Group..........................................................................................................................................................0-5

Introduction................................................................................................................................................................1-1

Course Goals (I).....................................................................................................................................................1-2

Course Goals (II)....................................................................................................................................................1-3

Course Objectives...................................................................................................................................................1-4

Course Content 1....................................................................................................................................................1-5

Course Content 2....................................................................................................................................................1-6

Overview Diagram 1..............................................................................................................................................1-7

Main Business Scenario.........................................................................................................................................1-8

PP-PI Overview..........................................................................................................................................................2-1

PP-PI Overview: Unit Objectives...........................................................................................................................2-2


PP-PI - Integration with the R/3 System................................................................................................................2-4

Application Areas of PP-PI....................................................................................................................................2-5

Positioning of PP-PI in the Enterprise Model........................................................................................................2-6

Functions of PP-PI..................................................................................................................................................2-7

Data Flow in PP-PI.................................................................................................................................................2-8

PP-PI Overview: Summary....................................................................................................................................2-9

Exercise Data........................................................................................................................................................2-10

Exercises...............................................................................................................................................................2-13

Solutions...............................................................................................................................................................2-15

Master Data: Overview..............................................................................................................................................3-1

Master Data: Unit Objectives.................................................................................................................................3-2


Master Data: Business Scenario.............................................................................................................................3-4

Master Data Overview............................................................................................................................................3-5

Material..................................................................................................................................................................3-6

Batch.......................................................................................................................................................................3-7

Resource.................................................................................................................................................................3-8

Production Version.................................................................................................................................................3-9

Master Recipe.......................................................................................................................................................3-10

Bill of Material - Definition.................................................................................................................................3-11

BOM Categories...................................................................................................................................................3-12

Master Data: Unit Summary.................................................................................................................................3-13

Materials.....................................................................................................................................................................4-1

Materials: Unit Objectives......................................................................................................................................4-2


Materials: Business Scenario..................................................................................................................................4-4

Material Master Records: Definition......................................................................................................................4-5

Material Master Records: Views............................................................................................................................4-6

Material Type.........................................................................................................................................................4-7

Control Using Material Type..................................................................................................................................4-8

Industry Sectors and Material Types......................................................................................................................4-9

Field Selection: Influencing Factors.....................................................................................................................4-10

Field Selection: Influencing Factors - Field Reference........................................................................................4-11

Field Selection: Field Selection Group (Example)...............................................................................................4-12

Field Selection: Field Selection Groups and Field References............................................................................4-13

Field Selection: Link Rules..................................................................................................................................4-14

Customized Material Master................................................................................................................................4-15

Creating a Customized Material Master...............................................................................................................4-16

Influencing Factors for Screen Sequences...........................................................................................................4-17

Screens for Material Master Maintenance............................................................................................................4-18

Materials: Summary.............................................................................................................................................4-19

Exercises...............................................................................................................................................................4-20

Solutions...............................................................................................................................................................4-26

R/3 Classification System...........................................................................................................................................5-1

R/3 Classification System: Unit Objectives...........................................................................................................5-2


R/3 Classification System: Business Scenario.......................................................................................................5-4

Classification..........................................................................................................................................................5-5

Classification in the R/3 System.............................................................................................................................5-6

R/3 Classification System.......................................................................................................................................5-7

R/3 Classification System: Example......................................................................................................................5-8

Class Types.............................................................................................................................................................5-9

Creating Classes...................................................................................................................................................5-10

Classifying Objects...............................................................................................................................................5-11

Classifying Objects for Process Manufacturing...................................................................................................5-12

Example : Classification of Resources.................................................................................................................5-13

R/3 Classification System: Summary...................................................................................................................5-14

Exercises...............................................................................................................................................................5-15

Solutions...............................................................................................................................................................5-19

Batches.......................................................................................................................................................................6-1

Batches : Unit Objectives.......................................................................................................................................6-2


Batches : Business Scenario...................................................................................................................................6-4

Material and Batch.................................................................................................................................................6-5

Batch Management in the Logistics Process..........................................................................................................6-6

Levels of Uniqueness of a Batch............................................................................................................................6-7

Changing Batch Levels...........................................................................................................................................6-8

Converting Batch Numbers....................................................................................................................................6-9

Classification of a Material and a Batch - Characteristic Inheritance..................................................................6-10

Creating Classes for Batches I..............................................................................................................................6-11

Creating Classes for Batches II............................................................................................................................6-12

The Batch Where-Used List at Several Production Levels..................................................................................6-13

Batch-Specific Material Unit of Measure.............................................................................................................6-14

Batch-Specific Units of Measure as an Attribute of a Batch................................................................................6-15

Integration of Batch-Specific Units of Measure...................................................................................................6-16

Physical Quantity and Active Ingredient Quantity...............................................................................................6-17

The Central Unit of Measure for Active Ingredients............................................................................................6-18

Relation of Units of Measure...............................................................................................................................6-19

Percentage and User-defined Calculation............................................................................................................6-20

Active Ingredient Characteristics.........................................................................................................................6-21

Linking Master Data I..........................................................................................................................................6-22

Linking Master Data II.........................................................................................................................................6-23

Maintaining Units of Measurement in the Material Master.................................................................................6-24

Batches : Unit Summary.......................................................................................................................................6-25

Exercises...............................................................................................................................................................6-26

Solutions...............................................................................................................................................................6-31

Resources: Customizing.............................................................................................................................................7-1

Resources: Customizing: Unit Objectives..............................................................................................................7-2


Resources: Customizing: Business Scenario..........................................................................................................7-4

Resources in the Company.....................................................................................................................................7-5

Resource Master Record........................................................................................................................................7-6

Functions of the Resource Category.......................................................................................................................7-7

Field Selection........................................................................................................................................................7-8

Capacity and Available Capacity...........................................................................................................................7-9

Capacity Categories for a Resource.....................................................................................................................7-10

Formulas in the Resource.....................................................................................................................................7-11

Example of a Formula..........................................................................................................................................7-12

Customizing a Default Resource..........................................................................................................................7-13

Resources: Customizing: Unit Summary.............................................................................................................7-14

Exercises...............................................................................................................................................................7-15

Solutions...............................................................................................................................................................7-22

Resources: Functions..................................................................................................................................................8-1

Resources: Functions: Unit Objectives..................................................................................................................8-2


Resources: Functions: Business Scenario..............................................................................................................8-4

Resource Data I......................................................................................................................................................8-5

Resource Data II.....................................................................................................................................................8-6

Resource Management Views................................................................................................................................8-7

Cost Center / Activity Type / Resource..................................................................................................................8-8

Creating a Resource................................................................................................................................................8-9

Resource Network................................................................................................................................................8-10

Classification of Resources..................................................................................................................................8-11

Available Capacity of a Resource........................................................................................................................8-12

Maintaining Avail. Capacity Using Shift Sequences...........................................................................................8-13

Assignments to the Personnel System (HR).........................................................................................................8-14

Reporting Functions for Resources......................................................................................................................8-15

Resources: Functions: Unit Summary..................................................................................................................8-16

Exercises...............................................................................................................................................................8-17

Solutions...............................................................................................................................................................8-29

Production Version.....................................................................................................................................................9-1

Production Version: Unit Objectives......................................................................................................................9-2


Production Version: Business Scenario.................................................................................................................9-4

Production Version: Definition..............................................................................................................................9-5

Production Version: Mass Processing (I)...............................................................................................................9-6

Production Version: Mass Processing (II)..............................................................................................................9-7

Recipe Editing........................................................................................................................................................9-8

Consistency Check.................................................................................................................................................9-9

Approval...............................................................................................................................................................9-10

Production Version: Unit Summary.....................................................................................................................9-11

Exercises...............................................................................................................................................................9-12

Solutions...............................................................................................................................................................9-16

Master Recipes: Operations and Phases...................................................................................................................10-1

Master Recipes, Operations, and Phases:Unit Objectives....................................................................................10-2

Overview Diagram 10..........................................................................................................................................10-3

Master Recipes, Operations, and Phases: Business Scenario...............................................................................10-4

Elements of a Master Recipe................................................................................................................................10-5

Structure of a Master Recipe (I)...........................................................................................................................10-6

Structure of a Master Recipe (II)..........................................................................................................................10-7

Functions of a Master Recipe...............................................................................................................................10-8

Non-Manufacturing Recipes................................................................................................................................10-9

Profile for the Recipe..........................................................................................................................................10-10

Recipe-Plant Assignment...................................................................................................................................10-11

Copying Recipes from Other Plants...................................................................................................................10-12

Reporting............................................................................................................................................................10-13

Recipe Header Data............................................................................................................................................10-14

Operations and Phases........................................................................................................................................10-15

Assignment of Primary and Secondary Resources.............................................................................................10-16

Standard and Default Values from the Resource...............................................................................................10-17

Relationships......................................................................................................................................................10-18

Relationships Between Master Recipes..............................................................................................................10-19

Scheduling in the Master Recipe........................................................................................................................10-20

Phase Duration...................................................................................................................................................10-21

Classification of Operations and Resources.......................................................................................................10-22

Checking the Recipe / Consistency Log.............................................................................................................10-23

Master Recipes, Operations, and Phases:Unit Summary...................................................................................10-24

Exercises.............................................................................................................................................................10-25

Solutions.............................................................................................................................................................10-34

Master Recipes: Materials........................................................................................................................................11-1

Master Recipes, Materials: Unit Objectives.........................................................................................................11-2


Master Recipes, Materials: Business Scenario.....................................................................................................11-4

Typical Material Flow in the Process Industry.....................................................................................................11-5

Material-Recipe Assignment (I)...........................................................................................................................11-6

Bill of Material - Definition.................................................................................................................................11-7

Material-Recipe Assignment (II)..........................................................................................................................11-8

Bill of Material - Example....................................................................................................................................11-9

BOM Item Categories........................................................................................................................................11-10

Material List.......................................................................................................................................................11-11

Classification of BOM Components..................................................................................................................11-12

Material Quantity Calculation I..........................................................................................................................11-13

Material Quantity Calculation II........................................................................................................................11-14

Material Quantity Calculation - Example...........................................................................................................11-15

Material Quantity Calculation - Process (I)........................................................................................................11-16

Material Quantity Calculation - Process (II)......................................................................................................11-17

Material Quantity Calculation Screen................................................................................................................11-18

Product Quantity Calculation.............................................................................................................................11-19

Component Quantity Calculation (I)..................................................................................................................11-20

Calculation Using Active Ingredient Quantities of Batches...............................................................................11-21

Calculation Using Physical Batch Quantities.....................................................................................................11-22

Component Quantity Calculation (II).................................................................................................................11-23

Master Recipes, Materials: Unit Summary........................................................................................................11-24

Master Recipes, Materials: Exercises................................................................................................................11-25

Solutions.............................................................................................................................................................11-38

Master Recipes: Control View.................................................................................................................................12-1

Master Recipes, Control View: Unit Objectives..................................................................................................12-2


Master Recipes, Control View: Business Scenario..............................................................................................12-4

Process Management............................................................................................................................................12-5

Creating and Downloading Control Recipes........................................................................................................12-6

Process Instructions and Control Recipes............................................................................................................12-7

Planning View and Control View........................................................................................................................12-8

PI Sheet.................................................................................................................................................................12-9

PI Sheet: Structure..............................................................................................................................................12-10

Process Instruction Maintenance........................................................................................................................12-11

Displaying Generated Process Instructions........................................................................................................12-12

PI Sheet Simulation in the Master Recipe..........................................................................................................12-13

Master Recipes, Control View: Unit Summary..................................................................................................12-14

Exercises.............................................................................................................................................................12-15

Solutions.............................................................................................................................................................12-21

Aspects of Co-Product Manufacturing.....................................................................................................................13-1

Aspects of Co-Product Manufacturing: Unit Objectives......................................................................................13-2


Aspects of Co-Product Manufacturing:Business Scenario...................................................................................13-4

Typical Material Flow for the Manufacture of Co-Products................................................................................13-5

Material Master....................................................................................................................................................13-6

BOMS for the Manufacture of Co-Products........................................................................................................13-7

Material Costing: Objectives................................................................................................................................13-8

Executing a Material Cost Estimate.....................................................................................................................13-9

Aspects of Co-Product Manufacturing: Unit Summary.....................................................................................13-10

Exercises.............................................................................................................................................................13-11

Solutions.............................................................................................................................................................13-18

Aspects of Quality Inspection During Production....................................................................................................14-1

Aspects of Quality Inspection During Production: Unit Objectives....................................................................14-2


Aspects of Quality Inspection During Production: Business Scenario................................................................14-4

Integration with Quality Management..................................................................................................................14-5

Inspection Lot.......................................................................................................................................................14-6

In-Process Inspection - Inspection Lot.................................................................................................................14-7

Assignment of Production Resource / Tool to Inspection Characteristics...........................................................14-8

Inspection Points, Partial Lots, and Batches........................................................................................................14-9

Specification of Batches Produced.....................................................................................................................14-10

Creating a Material Specification.......................................................................................................................14-11

In-Process Inspection - Example........................................................................................................................14-12

Aspects of Quality Inspection During Production: Unit Summary....................................................................14-13

In-Process Quality Inspection: Exercises..........................................................................................................14-14

Solutions.............................................................................................................................................................14-20

Engineering Change Management, Recipe Approval..............................................................................................15-1

Engineering Change Management, Recipe Approval: Unit Objectives...............................................................15-2


Engineering Change Management, Recipe Approval: Business Scenario...........................................................15-4

Objects Linked to Engineering Change Management..........................................................................................15-5

Why Use Engineering Change Management for Changes?.................................................................................15-6

Engineering Change Management: With and Without History...........................................................................15-7

Change Master Record (Change Number)...........................................................................................................15-8

Structure of a Change Master Record..................................................................................................................15-9

Change Documentation......................................................................................................................................15-10

Engineering Change Mgmt - Validity Period of Recipe Objects.......................................................................15-11

Engineering Change Request / Order.................................................................................................................15-12

Structure of an Engineering Change Request.....................................................................................................15-13

Comparison of Change Master Records and Engineering Change Requests / Orders.......................................15-14

Changing Master Recipes...................................................................................................................................15-15

System Status Network Object...........................................................................................................................15-16

System Status Network for Engineering Change Requests / Orders..................................................................15-17

Recipe Approval (General Procedure)...............................................................................................................15-18

Recipe Approval (Statuses I)..............................................................................................................................15-19

Recipe Approval (Statuses II)............................................................................................................................15-20

Digital Signature (I)............................................................................................................................................15-21

Digital Signature (II)..........................................................................................................................................15-22

Activating the Digital Signature.........................................................................................................................15-23

Engineering Change Management, Recipe Approval: Unit Summary..............................................................15-24

Exercises.............................................................................................................................................................15-25

Solutions.............................................................................................................................................................15-35

Summary and Conclusion........................................................................................................................................16-1

Summary and Conclusion: Unit Objectives.........................................................................................................16-2


Summary and Conclusion: Business Scenario.....................................................................................................16-4

Functions of PP-PI................................................................................................................................................16-5

Data Flow in PP-PI...............................................................................................................................................16-6

Life Cycle of a Process Order..............................................................................................................................16-7

Order Processing - Further Information...............................................................................................................16-8

Process Management - Further Information.........................................................................................................16-9

QM and Batches - Further Information..............................................................................................................16-10

Summary: Exercises...........................................................................................................................................16-11

Solutions.............................................................................................................................................................16-15

0

SAP AG 2001

LO305 Basic Data for Process Manufacturing

LO305LO305Basic Data for Process Manufacturing

Basic Data for Process Manufacturing

R/3 System Release 4.6C March 2001 5004 2382

0.2

SAP AG 2002

Copyright 2002 SAP AG. All rights reserved.

No part of this publication may be reproduced or transmitted in any form or for any purpose without the express permission of SAP AG. The information contained herein may be changed without prior notice.

Copyright

Notes on Trademarks: Some software products marketed by SAP AG and its distributors contain proprietary software

components of other software vendors. Microsoft®, WINDOWS®, NT®, EXCEL®, Word®, PowerPoint®, and SQL Server® are registered

trademarks of Microsoft Corporation. IBM®, DB2®, OS/2®, DB2/6000®, Parallel Sysplex®, MVS/ESA®, RS/6000®, AIX®, S/390®, AS/400®,

OS/390®, and OS/400® are registered trademarks of IBM Corporation. ORACLE® is a registered trademark of ORACLE Corporation. INFORMIX®-OnLine for SAP and INFORMIX® Dynamic ServerTM are registered trademarks

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Web Consortium, Massachusetts Institute of Technology. JAVA® is a registered trademark of Sun Microsystems, Inc. JAVASCRIPT® is a registered trademark of Sun Microsystems, Inc., used under license for technology

developed and implemented by Netscape. SAP, SAP Logo, R/2, RIVA, R/3, ABAP, SAP ArchiveLink, SAP Business Workflow, WebFlow, SAP

EarlyWatch, BAPI, SAPPHIRE, Management Cockpit, mySAP.com Logo, and mySAP.com are trademarks or registered trademarks of SAP AG in Germany and several other countries all over the

world. All other products mentioned are trademarks or registered trademarks of their respective companies.

0.3

SAP AG 1999

Process Industry (PP - PI)

Level 2

ProcessManufacturing

LO060 5 daysMaster Data for Process Manufacturing

LO305 5 days

KANBAN

LO235 2 days

Variant Configuration Part 1

LO990 5 days

Classification

LO985 3 days

Capacity Planning

LO230 5 days

Special Features of LISin Production

LO275 2 days ProcessManagement

LO315 3 days

Level 3

Production Planning

LO210 5 days

Process FlowScheduler

LO320 3 days

Logistics Info Planning

LO935 2 days

Logistics Info System (LIS)

LO930 2 days

Detail Functions ofProcess Orders

LO310 5 days

Variant Configuration Part 2

LO991 3 days Batch Management

LO955 3 days

0.4

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Prerequisites

LO060 - Planning & Control for Process Manufacturing

0.5

SAP AG 1999

Audience

Members of project teams who are responsible for the introduction of material masters (including batch master records), resources, and master recipes (including BOMs) into the R/3 System.

Duration: 5 days

Target Group

Note: This training material is not intended to be used as self-study material but rather to complement the

trainer‘s explanations. It therefore includes space for noting down additional information.

1

SAP AG 1999

Course goals

Course objectives

Course content

Course overview diagram

Main business scenario

Introduction to course

Contents

Introduction

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SAP AG 1999

This course will prepare you to maintain the basic data required for process manufacturing.This includes:

Material master and batches

Resources

Production versions

Master recipes

Material BOMs

Course Goals (I)

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SAP AG 1999

Furthermore, you will be introduced to the following special aspects of process manufacturing:

Using engineering change management to edit a master recipe that requires approval

Visually reproducing the manufacture of co-products and costing of the materials involved

Planning a quality inspection during production

Preparing master data for active ingredient management

Course Goals (II)

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SAP AG 1999

Make the most important system settings regarding the material master, resources, and master recipes with material lists

Describe the effects of these system settings on process manufacturing

Use engineering change management for recipe approval

Visually reproduce the manufacture of co-products

Perform a quality inspection in the system during production

At the conclusion of this course, you will be able to:

Course Objectives

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Unit 9 Production Versions

Unit 10 Master Recipes, Operations and Phases

Unit 11 Master Recipes,Materials

Unit 12 Master Recipes,Control View

Unit 13 Aspects of Co-ProductManufacturing

Unit 1 Introduction

Unit 2 PP-PI Overview

Unit 3 Master Data: Overview

Unit 4 Materials

Unit 5 R/3 Classification System

Unit 6 Batches

Unit 7 Resources: Customizing

Unit 8 Resources: Functions

Preface

Course Content 1

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SAP AG 1999

Unit 16 Summary and Conclusion

Unit 14 Aspects of Quality Inspection During Production

Unit 15 Engineering ChangeManagement, Recipe Approval, and Further Functions

Course Content 2

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PP-PI Overview

Master Data: Overview

Materials

R/3 Classification System

Batches

Resources: Customizing

Resources: Functions

Production Version

Master Recipes: Operations and Phases

Master Recipes: Control View

Aspects of Co-Product Manufacturing

Aspects of Quality InspectionDuring Production

Engineering Change Management,Recipe Approval

1111

11

22

33

44

55

66

77

88

99

1010

1212

1313

1414

1515

IntroductionIntroduction

Summary and Conclusion1616

Master Recipes: Materials

Overview Diagram 1

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As a member of a project team in a company, you are responsible for creating the basic data in the R/3 System.

The company is a process manufacturing enterprise with chemical and pharmaceutical divisions. It produces detergent, fertilizer, and headache tablets.

The basic data that you will define covers materials, batches, classes, resources, and production versions with master recipes and material BOMs.

Main Business Scenario

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Integration of PP-PI with the R/3 System

Application areas

Functions for representing process manufacturing in the R/3 System

Contents:

PP-PI Overview

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PP-PI Overview: Unit Objectives

Describe how PP-PI is integrated in the R/3 System

Tell which application areas exist for PP-PI

Name the functions PP-PI contains

At the conclusion of this unit, you will be able to:

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Introduction


Materials


Batches



Production Version

Master Recipes: Operations andPhases





1111

11

33

44

55

66

77

88

99

1010

1212

1313

1414

1515



22 PP-PI Overview

Overview Diagram 2

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PP - SOPSales & Operation Planning

PP - MPSMaster Prod. Scheduling

PP - MRPMaterial Rqmts Planning

PP - CRPCapacity Rqmts Planning

PP - SFCShop Floor Control

PP - PCProduct Costing

.

.

.

PP - PIProcess Industries

IntroductionIntroduction

R/3R/3Client / ServerClient / Server

ABAP/4ABAP/4

FIFI

COCO

AMAM

PSPS

WFWF

ISIS

MMMM

HRHR

SDSD

PMPM

QMQM

PPPP

PP-PI - Integration with the R/3 System

The R/3 System contains integrated application software that is based on an open three-level client/server architecture. It covers the entire range of business functionality a company requires. The system’s efficiency is achieved through an integration of different application components that represent a network of business functions. This guarantees a consistent execution of all business processes in every area of a company. All components work on the basis of real-time processing.

With its PP-PI component, SAP offers a set of functions that meet the requirements of production planning and control in process industries.

The PP-PI component is a fully integrated production planning and control system designed for process industries. Since it is an integral part of the R/3 production planning component PP, it is linked to other PP subcomponents such as Sales & Operations Planning (PP-SOP), Material Requirements Planning (PP-MRP), Capacity Requirements Planning (PP-CRP), and Shop Floor Control (PP-SFC).

In addition, PP and PP-PI are fully embedded in the logistics chain, consisting of the R/3 components Sales and Distribution (SD), Materials Management (MM), Production Planning (PP), and Quality Management (QM).

Furthermore, PP-PI is linked to applications of other business areas such as the Human Resources System (HR) and Controlling (CO).

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Process manufacturingProcess manufacturing

Target markets:

Batch manufacturingBatch manufacturing

CoCo--productsproducts / by/ by--productsproducts

Fully and partially automated linesFully and partially automated lines Lines with variable usagesLines with variable usages Variable production parametersVariable production parameters Quality assuranceQuality assurance Batch and production recordsBatch and production records

Chemical industry

Pharmaceutical industry

Food industry

Process-oriented electronics industry

Application Areas of PP-PI

PP-PI is designed for the batch-oriented process manufacturing company that uses integrated planning for its production processes. Ideally, PP-PI is used in companies of the chemical and pharmaceutical industry, the food, beverages, and tobacco industry as well as the process-oriented electronics industry.

PP-PI meets the following typical requirements of such companies:The production process is carried out in batches, that is, non-reproducible units that are characterized by certain specifications. In addition, many materials entering the manufacturing process are managed in batches with varying specifications.During the different manufacturing steps, products, co-products, by-products, and remaining materials are produced. If several planned materials are manufactured during one production run, they are called co-products.Information is exchanged between the process planning and the process control levels. Production is carried out in automated or partially automated lines. Part of the manufacturing instructions must therefore be displayed in natural language to be read by a process operator, whereas part of them must be prepared for an automatic process control system.The usage of the production lines is variable and process control is carried out using variable parameters that differ from batch to batch.To ensure the quality of the product, a constant coordination with quality assurance is indispensable.

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It must be possible to archive and evaluate the planning data and actual data of the manufacturing process for each batch.

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Company management level

Production management level

Process control level

Business applications

Production planning - process industries

Process control systems

PP-PI

PP

AMCOFI

PCS

SD

MM

QM

Positioning of PP-PI in the Enterprise Model

The graphic shows the hierarchical structuring of information of an individual company. The following levels exist:

Company management levelProduction management levelProcess management level

PP-PI is situated at the production management level between the upper-level business applications and the lower-level process control systems.

PP-PI is designed to close the information gap between business applications and process control.

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PCS

Process controlsystem (autom.)

PI sheetLaboratory

information syst.

LIMS PI sheet(manual)

Master recipe

Resource

MaterialMaterial

Master dataMaster data

Production planningProduction planning

Qualitymanagement

Processplanning/

orders

Processmanagement

Process datadocumentation/

evaluation

Functions of PP-PI

PP-PI comprises the following functional areas :Resource management: The PI-specific master data of resources describes all means of production and persons involved in the production process.Master recipe management: The PI-specific master data of master recipes describes the manufacture of one or more materials in one production run without relating to a particular order. Master recipes are the basis for process orders.Process planning comprises the planning of process orders. Process orders are created on the basis of master recipes. They describe and monitor the actual production process.Process management coordinates the transfer of data between PP-PI and the process control level. It can be used in fully automated, partially automated, and manually operated plants.Process data documentation and evaluation enables a detailed documentation and evaluation of all planned and actual values of a process.

PP-PI is integrated with, for example:R/3 Quality Management. Via a special interface, external laboratory information systems (LIMS) can be linked to R/3 QM.The higher-level planning components of R/3. Production requirements for PP-PI are created in R/3 Material Requirements Planning. Via a special interface, you can also transfer requirements from an R/2 System or an external planning system to PP-PI.

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The master data and functions of R/3 Materials Management (such as material, inventory management).

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•Material master•Bill of material

•Proc. units•Personnel

•Automatic control•Manual control (PI sheet)

Manually

QMQM

MMMM

PPPP

PP-PIPP-PI

Planned orderPlanned orderProduction reqmts

MaterialsMaterialsMaster recipeMaster recipe Process orderProcess order

ResourcesResources

Process data documen-tation & evaluation Process managementProcess management

ProcessProcessmessagesmessages

Control recipe:Control recipe:proc. instructionsproc. instructions

Process controlProcess controlsystemsystem

Processcontrol level

Data Flow in PP-PI

A production process is triggered by production requirements. Production requirements are created in material requirements planning in the form of planned orders. Planned orders define the basic dates and planned production quantities.

During process planning, planned orders are converted into process orders. The basic dates and production quantities are copied from the planned order. The actual production dates are calculated using the basic dates. You can also create a process order manually.

A process order provides a detailed description of the actual production of one or more materials in one production run. It is the main control instrument in production, describing and monitoring all planned and actual data relating to production.

A master recipe is used as the basis for a process order. It defines, for example, the planned resources and material components.

After a process order has been released for production, the process instructions maintained in the order are bundled into control recipes by process management. The control recipes are either transferred to a process control system via a specific interface or are displayed online in the form of a process instruction sheet (PI sheet) that can be read and maintained by process operators.

Process management in turn receives process messages from the process control level and transfers them to various destinations. For instance, it is possible to record confirmations for the process order, transfer actual values of the process to functions for process data documentation and evaluation, post

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material consumptions or production yields as goods movements and transfer quality data to Quality Management results recording.

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SAP AG 1999

PP-PI Overview: Summary

The PP-PI component covers the requirements of production planning and production control in process industries.

The application area of PP-PI is the batch-oriented, process manufacturing enterprise.

The process order describes in detail the concrete production of a material in one production run. The source for the order is the master recipe.

Process management coordinates the data exchange between PP-PI and the process control level.

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2.10Exercise Data

Key to the symbols in the exercises and solutions:

Exercises

Solutions

Unit Objectives

Business Scenario

Tips & Tricks

Warning

Data Used in Exercises

Data Data in Training System

Data in IDES System

Plant 1100 1100

Master recipes T-DET100 T-DET100

T-RC1## T-RC100

T-TAB## N-2100

T-ICE## T-ICE00

COLORS COLORS

T-JUI100 T-JUI100

Resources T-DTM1## T-DTM100

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T-DTR1## T-DTR100

T-DTR2## T-DTR200

T-DTR3## T-DTR300

T-DTA1## T-DTA100

T-DTG1## T-DTG100

T-IC1## T-IC100

T-JM100 T-JM100

Secondary resource T-DTT1## T-DTT100

Material, ROH T-RD1## T-RD100

T-RD2## T-RD200

T-RD4## T-RD400

T-RD5## T-RD500

T-RF1## T-RF100

T-RF2## T-RF200

T-RF3## T-RF300

T-RJ1## T-RJ100

T-RJ2## T-RJ200

T-RJ3## T-RJ300

T-RI5## T-IC-R2006

Material, PIPE T-RD3## T-RD300

Material, HALB T-FF3## T-FF300

T-Hat2## N-2100

Material, FERT T-FD1## T-FD100

T-FF1## T-FF100

T-FJ1## T-FJ100

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Characteristics M100 M100

M200 M200

M700 M700

M800 M800

M900 M900

Classes 023_14 023_14

023_15 023_15

023_20 023_20

023_21 023_21

## = 01 - 20

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2.11Exercises

Unit: PP-PI Overview: Overview PP-PI

Topic: Logging on to the System/ Menu Paths

At the conclusion of these exercises, you will be able to:

Log on to the system

Find the menu paths for process industries

Create a user menu

You are a member of your company's project team and are responsible for creating the basic data in the R/3 System.

Your company is a process manufacturing enterprise with chemical and pharmaceutical divisions. It produces detergent, fertilizer, and headache tablets.

The basic data that you will define includes materials, batches, classes, resources, and master recipes.

1-1 Logging on to the system

1-1-1 Log on to the PC

USER:PASSWORD:

1-1-2 Log on to the R/3 System

CLIENT:USER:PASSWORD: INITLANGUAGE: EN

1-2 Overview of the menu paths for process industries in the SAP menu

Familiarize yourself with the menu paths in the SAP menu.Familiarize yourself in particular with the master data that can be selected and maintained in Production – Process

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1-3 Creating a role (user role)

Create your own role by selectively copying the role LO305_EN and giving it the name LO305_## with the description Role for LO305 group ## . Do not copy the user that is already assigned.

Add the SAP homepage to your role. The web address is www.sap.com.

Move your web address so that it is below Customizing in your role menu.

Assign your user ID to the role.

Save your role.

Open a second session and select the menu for your activity group. In this session, the changes are effective.

Compare the structure of your user menu with that of the SAP standard menu.

Close the first session.

Your user menu was specifically created for this course and contains all transactions you need to do the exercises. The structure of the user menu can be adjusted at any time to meet your individual needs. For this reason, the menu paths in the solutions refer to the SAP menu, not to the individual user menu.

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2.12Solutions

Unit: PP-PI Overview

Topic: Logging on to the System/Menu Paths

1-1 Logging on to the System

1-2 Overview of the Menu Paths for Process Industries

Master Data: Material master

Production Versions

Resources

Master Recipes

Engineering Change Management

Production Resources / Tools

1-3 Choose Create role.

Enter role LO305 DE.

Choose Copy role

from role: LO305_DE to role: LO305_##

Choose Copy selectively.

X Personalization

Choose Continue.

Choose Change.

Description: Role for LO305 group ##

Choose the Menu tab page.

Choose Other.

X Web address or file

Choose Continue.

Text: For example, SAP Homepage

Web address or file: www.sap.com

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Choose Continue.

Select the Web address and use the Move down button to move it to another position.

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User tab page

User ID: PI-##

Save

Choose Create a new session.

Choose User menu.

In the first session, choose System -> Delete mode.

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3

SAP AG 1999


Material

Batch

Resource

Production version

Master recipe with material BOM

Contents:

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3.2

SAP AG 1999

Master Data: Unit Objectives

Distinguish between the definitions of material and batch

Define resources

Explain what a production version is

Define the components of a master recipe along with its material BOM


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3.3

SAP AG 1999

Overview Diagram 3

PP-PI Overview

Materials

Introduction


Batches



Production Version






1111

22

44

11

55

66

77

88

99

1010

1212

1313

1414

1515


Master Recipes: Materials33 Master Data: Overview

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3.4

SAP AG 1999

Master Data: Business Scenario

Before you start maintaining master data in the R/3 System, get an overview of the R/3 terminology and the following PP-PI basic data objects:

Material and batch

Resource

Production version

Master recipe with material BOM

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3.5

SAP AG 1999

ResourceResource

Master recipeMaster recipe

...

Master Data Overview

BatchBatchBatch

BatchBatchBatch

BatchBatchBatch

Production versionProduction version

Material BOMMaterial BOM

MaterialMaterial

Master data is data in the R/3 System that remains unchanged over an extended period of time. It contains information that is used in the same manner for similar objects.

The material is the central master record in Logistics. In general, SAP defines a material as a substance or commodity that is bought or sold on a commercial basis, or is used, consumed or created in production.

A batch is a subset of a material with unique specifications. The batches of one material are managed separately in stock. With regard to the production process, a batch is a quantity of a material produced in a given production run. This quantity, therefore, represents a non-reproducible unit with unique specifications.

The PI-specific master data of the resource describes all means of production and persons involved in the production process.

A production version determines which alternative BOM is used together with which master recipe. The PI-specific master data of master recipes describes the manufacture of one or more materials in one

production run without relating to a particular order. Material BOMs are used to represent the structure of products that a company manufactures.

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SAP AG 1999

Material

Substance or commodity that is bought or sold on a commercial basis, or is used, consumed, or created in production. A material can also be a service.

MaterialMaterial

MaterialMaterial

A material master record contains data of a descriptive nature (such as size, dimension, weight) and data with a control function (such as material type).

In addition to this data, which can be maintained by the user, the material master record also contains data that is automatically updated by the system (such as stock levels).

An alphanumeric material number identifies a material master record in the system. This material number is unique at the client level.

Depending on its function or usage, master record data is assigned to different organizational levels (such as plant, storage location, sales organization).

A material master record comprises different views. A view groups all data on a material created by a particular department (such as Purchasing, MRP, Work scheduling) in the master record.

Depending on their usage and requirements, material master records are grouped into material types.

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3.7

SAP AG 1999

Batch

Subset of the total quantity of a material held in stock. This subset is managed separately from other subsets of the same material.

Quantity of a material produced during a given production run. A batch represents a non-reproducible, homogeneous unit with unique specifications.

...

BatchBatchBatch

BatchBatchBatch

BatchBatchBatch

BatchBatchBatch

MaterialMaterial

In a process manufacturing company, production is usually executed in batches. In addition, many materials entering the process are managed separately in batch stocks with different specifications.

In the R/3 System, batch master records depend on the corresponding material master record. Batches are created for a material.

In general, the data of a material master record is valid for all batches assigned to it. In contrast, a batch master record contains data that uniquely identifies a batch and characterizes it as a non-reproducible unit.

A batch master record is identified by an alphanumeric batch number. In accordance with the structure of your plant or company and your operational requirements, you can choose whether you want the batch number to be unique in combination with a material and a plant, in combination with a material number, or at client level.

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3.8

SAP AG 1999

Processingunit

Labor

Resource

Means of production and persons in the production process that have capacities assigned to them. Resources are subdivided into resource categories.

Resources

Waste disposal facility

Energy

Transport

Resources are the main planning instruments of production planning and control. The data you maintain for a resource is, for example, used for:

Scheduling process ordersCapacity requirements planningProduct and order costing

Resources are grouped in resource categories on the basis of their usage and function. You can define your own resource categories in Customizing.

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3.9

SAP AG 1999

Production Version


A production version determines which alternative BOM is used together with which master recipe to produce a material or create a master plan for a material.

More than one production version for different validity periods and lot-size ranges can be assigned to a material.

Production versions are used both in discrete manufacturing and process manufacturing.

Production versions are used in Sales & Operations Planning (SOP), material requirements planning (MRP), process order creation, and product costing to select the most suitable task list or recipe and the corresponding material list.

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3.10

SAP AG 1999

Master Recipe

EBF/ISA(S88)/NAMUREBF/ISA(S88)/NAMUR

Proc. planning Proc. control

Control information

Quality inspec. data

Steps in the prod. process

Resources

Materials

Master recipe

Process order Process order Control recipeControl recipe

A master recipe defines the following data that is required for the manufacturing of materials without relating to a particular order: processing steps, resources, material components, data for quality inspection during production, and control information for the process control level.

Master recipes have a planning and a control view. The planning view comprises the planning of operations, materials, resources, and inspection characteristics, realizing links to the R/3 application components PP, MM, SD, WM, and QM. The control view contains information required for communicating with the process control level.

The master recipe is the basis for creating process orders. A process order describes an actual production process. It contains all the information specified during process planning, such as the production date and quantities to be produced.

A control recipe contains all the information necessary for the execution of a process order by a certain process control system or a line operator. Control recipes are generated from the process instructions in a process order and sent to the corresponding destination in process control. Process instructions are defined in the master recipe the process order is based on.

Three organizations have defined the data that must be included in the standard recipe maintenance of the PP-PI module:

The European Batch Forum (EBF)The Instrument Society of America (ISA; with standards S88)

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NAMUR (Norms working committee for measuring and control techniques in the chemical industry).

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3.11

SAP AG 1999

Bill of Material - Definition

Bill of material

A complete, fully structured list of the components that

make up a product or assembly. The list contains the object

number of each component together with the quantity and

unit of measure.

Bill of materialBill of material

MaterialMaterial(to be produced)(to be produced)

Materialcomponent 10




Bills of material (BOMs) contain important basic data used in many different organizational areas. BOM data is, for instance, important for:

Material requirements planningMaterial staging during productionProduct costing

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3.12

SAP AG 1999

BOM Categories

Document

Material BOM

Material

Sales order BOM WBS BOM

Doc. structure Equipment BOM Funct. loc. BOM

BOM categories are used to represent different objects.

Material BOMs are used to represent the structure of products that a company manufactures.

Sales order BOMs are used to represent the specific bill of material used to manufacture a product for a specific sales order.

Work breakdown structure BOMs (WBS BOMs) are used to enter components in the project system.

A document may consist of several different documents such as a program, drawings, manuals, and photos. Document structures are used to represent this. They are created for a single document information record and are maintained in the R/3 document management system.

Equipment BOMs are used in Plant Maintenance to describe the structure of a piece of equipment and to assign spares to the piece of equipment for maintenance purposes.

Functional location BOMs are used in Plant Maintenance to tie equipment to a particular location within a facility.

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3.13

SAP AG 1999

Master Data: Unit Summary

The most important master data in PP-PI are material, resource, and master recipe.

A batch is a subset of a total quantity of a material with unique specifications.

Resources are means of production and persons involved in the production process that have capacities assigned to them.

Production versions serve to assign a master recipe to a material BOM.

A master recipe defines processing steps, resources, material components, QM data, and control information required for the manufacturing of materials without relating to a particular order.

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4

SAP AG 1999

Material Master Record: Definition

Material Type

Field Selection

User-Defined Material Master Record

Creating Material Master Records

Contents:

Materials

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4.2

SAP AG 1999


Materials: Unit Objectives

Define the term "material master"

Create a material type

Make field selection settings

Make user-specific configurations

Create material master records

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4.3

SAP AG 1999

PP-PI Overview


Introduction


Batches



Production Version






1111

22

33

11

55

66

77

88

99

1010

1212

1313

1414

1515



44 Materials

Overview Diagram 4

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4.4

SAP AG 1999

Materials: Business Scenario

Your company is going to put a new detergent on the market.

You are responsible for the definition of the material masters that are required for the new product:

Raw materials

Finished product

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4.5

SAP AG 2001

Material Master Records: Definition

MaterialMaterial

Material master recordMaterial master record

Substance or commodity that is bought or sold on a commercial basis, or is used, consumed, or created in production. A material can also be a service.

Data record containing all data required for managing a material; the data is arranged according to various criteria.

Materials are created as material master records and identified using a material number. A material master record contains data of a descriptive nature (such as size, dimension, weight) and data

with a control function (such as material type). In addition to this data, which can be maintained by the user, the material master record also contains

data that is automatically updated by the system (such as stock levels). An alphanumeric material number identifies a material master record in the system. This material

number is unique at the client level. Depending on its function or usage, master record data is assigned to different organizational levels

(such as plant, storage location, sales organization). A material master record comprises different views. A view groups all data on a material created by a

particular department (such as Purchasing, MRP, Work scheduling) in the master record.

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4.6

SAP AG 1999

A BXX XX

Materialmaster record

St

Purchasing Sales

Basic data

MRP

Plant / Storage location stock

Accounting

Storage

Qualitymanagement

Work scheduling

Forecasting

Classification

Warehousemanagement

Material Master Records: Views

Each department of a company needs to maintain different information on a material. Therefore, the material master record comprises different views.

A view groups all data on a material created by a particular department (such as Purchasing, MRP, Work scheduling) in the master record.

In accordance with their different usages, the materials of a company are grouped together in material types. The material type controls, for example, which views of a material master record can be accessed.

Master record data is assigned to different organizational levels of the R/3 System. When maintaining specific views, you must therefore enter the organizational units (such as plant, storage location, and purchasing organization) for which you want to maintain the data.

For each user, you can specify which views of the material master record may be maintained or displayed.

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4.7

SAP AG 1999

Material typeMaterial type

Material Type

Term for the subdivision of materials into different groups such as raw materials, semi-finished products, finished products, configurable materials, process materials, intra materials.

The material type controls, for instance, the material's procurement type, screen sequence and field selection, inventory management type, and account determination in financial accounting.

Within a company, different materials are used for different purposes. Material master records must therefore meet different requirements with regard to views to be maintained and control of certain business transactions. To achieve this, materials are assigned to different material types in the R/3 System.

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4.8

SAP AG 1999

Field selection and screen sequence

General indicator (pricing for pipeline,process, configurable)

Costing control

Item category group in SD

Views for material maintenance

Procurement type

Type of inventory management (quantity/value)

Number assignment (check external numbers Y/N)

Assignment of account categories and references

Authorization group

MaterialMaterial

Mat. typeMat. type

Control Using Material Type

You specify a material type for each material. It is part of the general data of a material. The material type defines the following:

Which procurement type is set, that is, whether external or internal orders are possible Which views can be maintained by which user departments Whether material numbers can be checked against a number range Whether stock quantities and stock values can be updated Which material accounts are assigned The field selection and screen sequence in material master maintenance Costing control for a material The determination of item category groups for sales documents Control of data access via authorization groups

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4.9

SAP AG 1999

SAP R/3 Material Types

ROH - Raw materials

HALB - Semi-finished products

FERT - Finished products

KMAT - Configurable materials

HAWA - Trading goods

INTR - Intra materials

PROC - Process materials

VERP - Packaging materials

Semi-finished products

Raw materials

Raw materials

Semi-finished products

Finished products Finished products

Miscellaneous Miscellaneous

Industry sectorPharmaceutics

Industry sectorChemical

.

.

.

Industry Sectors and Material Types

The material types ROH (for raw materials), HALB (for semi-finished products), FERT (for finished products) and KMAT (for configurable materials) are generally used in production.

The material types PROC and INTR are specifically used in process industries:The material type PROC (process material) can be used to represent the manufacture of co-products that is not initiated by material requirements planning.The material type INTR (intra material) describes materials that exist only temporarily in a process.

The industry sector determines to which branch of industry the material is assigned. The industry sector determines which fields are required fields in material master data maintenance.

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4.10

SAP AG 1999

..................

..................

..................

?

Transaction

Procurementindicator

Material type

Plant

Industry sector

SAP / user

Field selection

Field Selection: Influencing Factors

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4.11

SAP AG 2001

Field Selection: Influencing Factors - Field Reference

User

Procurement indicators E / F

Transaction MM02

Industry sector C

Plant 1100

Material type HALB HALB

1100

C

KB

MM02

E / F

Influencing factor Field reference

Examples

Material type PI01 Z01

SAP SAP1SAPR

Material type HALB

Each influencing factor is assigned its own field reference for field selection. You can define field references for the material type, plant, and industry sector. The field references for the other influencing factors are predefined.

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4.12

SAP AG 1999

Field nameMARA-FERTH

Field nameMARA-FORMT

Field nameMARA-KZUMW

1:nField selectiongroup

015

Field Selection: Field Selection Group (Example)

The material master fields are grouped in field selection groups.

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4.13

SAP AG 2001

Field Selection: Field Selection Groups and Field References

T006A-MSHT

Field selectiongroup 1

MARA-MATKLMARA-MEINS

…

Field selectiongroup 2

Field selection (field sel. grp 1) Field selection (field sel. grp 2)

Field ref. Hide Disp. Reqd.Opt.

P

PROC

ROH

SAP1

(and so on)

Field ref. Hide Displ. Reqd. Opt.

P

PROC

ROH

SAP1

All field selection groups are assigned to all field references. The field options (hide, display, required entry, optional entry) are defined for each field selection group

and field reference.

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4.14

SAP AG 1999

++

+

+

+*

** * *

-

-

-

-

-

- - - -

*

*

.

..

Link rulesfor field selection groups

.

.

+

.

.

.

+

-

*

.

.

.

+

.

*

.

.

.

+ - *

Material type

Plant

Industry sector

Transaction

Procurementindicator

SAP / user

Examples

Field sel. Field sel. Field sel.grp 1 grp 2 grp 3

Field Selection: Link Rules

Field references of several influencing factors (such as the material type or plant) determine the field selection.

The field references define the field options (hide, show, required entry, optional entry) for the indvidual field selection groups.

All field option entries valid for each operation are linked together per field selection group. The link rules shown in this graphic determine the result of the field selection for a field selection

group. In order of priority, the signs mean the following:

- Hide * Show

+ Required entry . Optional entry

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4.15

SAP AG 1999

Screen Screen modulesmodules

Basic data Basic data

Sales

Purchasing

ScreensScreensScreen Screen

sequencessequences

Customized Material Master

You can structure the material master according to the requirements of your company:

You can remove screens that you do not need from the screen sequence.

You can create your own screens by adding or deleting screen modules.

You can influence individual fields in the screen modules.

Customized material master screens support sufficient data maintenance by creating entry dialogs specific to your company's data requirements.

The material master is a set of logical screens organized in a specific sequence when more that one view is selected. This organization of logical screens is referred to as a screen sequence.

Each logical screen consists of several programmed sets of material master fields. In the R/3 System, these sets are referred to as screen modules or subscreens. The fields assigned to each screen module cannot be changed in Customizing.

In Customizing for the Material Master you can:Maintain screen sequencesMaintain logical screensMaintain the order of logical screens in a screen sequence Determine which screen modules are displayed on which logical screens Assign field selection influencing factors to a screen sequence Assign a user or group of users to a screen sequence Enter default values for the organizational level, the industry sector, and the logical screens for a user or a group of users

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4.16

SAP AG 1999

a) Use standard screen modules (recommendation)

b) Use field selection to show/hide fields

c) Program and integrate user-specific screen modules

d) Define the sequence of screen modules in the logical screen

Logical screen

Copy standard screen sequence (such as "01”)

Use your own name range for screen sequence => Y*, Z*

Delete, extend, or change logical screens in the new sequence

Define sequence of logical screens in the screen sequence

Link the new screen sequence to influencing factors

Creating a Customized Material Master

Note: When you create your own logical screens, it is a good idea to use the standard screen modules that

already exist. You need your own screen modules if you require non-standard field groupings or new fields. To create your own screen modules, copy the standard program SAPLMGD1 into your own function

group (for instructions, see IMG). Then you can create the subscreens you require in the new function group.

Append structures are defined in the Data Dictionary so that you can integrate your own fields. You can only integrate fields from user-specific tables and user-specific subsreen containers in the

SAPLMGMM program by using modifications. You must use Customizing to create your own material master dialogs.

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4.17

SAP AG 1999

Influencing Factors for Screen Sequences

Screen sequence 01 Y1

Screen ref. transaction 01 01

Screen ref. user TEMPLATE *

Screen ref. material type * *

Screen ref. industry sector * *

Transaction

User

Material type

Industry sector

Influencing factors:

Combinations of screen

references:

You can create a screen reference for user, material type, and industry sector. The screen references for transactions are predefined. The screen sequence becomes valid for the appropriate user, material types, and industry sectors when

you assign the screen references to this screen sequence. In the example in the graphic, the screen sequence 01 is valid for all users who are assigned to the

"Template" reference, irrespective of industry sector and material type.

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4.18

SAP AG 1999

Initial s

creen

Main d

ata scre

ens

Texts

Additional d

ata screens

Workscheduling

MRP SalesForecasting Accounting

Units ofmeasure

Documentdata

Administrativedata

Consumption

Material

St

t A A

A

KMTKMT

Purchas-ing

Screens for Material Master Maintenance

To maintain a material, you enter the material number on the initial screen. You then select the organizational levels and views of the main data screens.

The data screens on the main level are displayed in a standard sequence. However, you can jump from screen to screen and thus interrupt the standard sequence.

To reach the additional data screens, choose the menu option Extras from within the corresponding view.

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4.19

SAP AG 1999

Materials: Summary

The material master is the central master record for logistics.

The material is identified using the material number.

Maintenance takes place in individual material views.

The material type groups materials and controls how they are processed.

Material types that are commonly used in PP-PI are: ROH, HALB, FERT.

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4.20Exercises

Unit: Materials

Topic: Material Master Records


Make system settings for materials

Create material master records


You are responsible for the definition of the material masters that are required for the new product:

Raw materials

Finished product

1-1 Settings for material types

In the IMG (implementation guide/Customizing), display the material types that are defined for finished products, semi-finished products, and raw materials.

1-1-1 Write down the settings for the parameters in the table below.

Parameters Finished Products

Semi-finished Products

RawMaterials

Material type

Are internal orders allowed?

Are external orders allowed?

Which of the following fields are selected in the User departments area?

Sales?

Costing?

Purchasing?

MRP?

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RawMaterials

Work scheduling?

Which price control is set?

Does a quantity update take place for the material type?

1-1-2 What does the External no. assignment w/o check indicator specify?

______________________________________________________

______________________________________________________

______________________________________________________

1-1-3 What does the With qty structure indicator specify?

______________________________________________________

______________________________________________________

1-2 Creating a new material type

Copy the material type for the semi-finished product HALB.

Enter a new material type PI## (## = group number).

The description of the material type is "PI Group ##".

Set the following parameters for the new material type:

– External and internal orders are allowed.

– Externally assigned material numbers are checked against a number range.

– Product costing with a quantity structure (BOM, routing)

– For materials of this material type, the following areas may be maintained:

Work scheduling Classification

MRP Storage

Basic data Plant and storage location stock

Costing

– In all plants (valuation areas), quantities and values are to be updated for materials of this material type.

– All materials of this material type (not changeable) are to be valuated according to the moving average price.

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– Account assignment is to take place according to account category reference 0008, the same as for material type HALB.

– Save the material type.

1-3 Field selection settings for the material type

The material type PI## is used for semi-finished products that are copied from an external system.

Make the following material fields a required entry for material type PI##:

Old material number (MARA-BISMT)Cross-plant material status (MARA-MSTAE)

1-3-1 To which field selection groups are these fields assigned? ____________

1-3-2 Is the content of this field copied (proposed) when you create using a reference material? __________

1-3-3 Which other field belongs to these groups ? ______

1-3-4 Copy field reference Z## and specify that these fields are required fields.Copy the field reference for the semi-finished product HALB.

Save your settings.

1-3-5 Assign the field reference Z## to your material type PI##.

1-3-6 Test your settings by creating material T-PI## with material type PI-## (only the Basic data 1 + 2 views). Notice which views the system displays.

Notice that the fields previously processed are now required entries. You can make any entry in the old material number fields of this material. Use material status 01 with today as the valid from date. Cancel without saving.

1-4 Creating a customized material master

Set up a user-specific screen sequence Y# or Z# (free number) for material master maintenance.Use screen sequence 21 "Std ind.(short) tab" as a template for your screen sequence Y# or Z# "Screen sequence: PI Gr.##".

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1-4-1 From data screen 08 (basic data 2), copy the screen module environment (2010) to data screen 07 (basic data 1). Then delete data screen 08 and name data screen 07 "basic data".

1-4-2 Control your screen sequence Y# or Z# in a way that the following sequence appears:

Screen 1 Basic dataScreen 2 MRP 1 - 4Screen 3 Work schedulingScreen 4 General plant data/storageScreen 5 Classification

The rest of the sequence after these screens remains the same.

1-4-3 The screen sequence is to be valid for your user PI-##. Define a screen reference for your user and create a new screen sequence control (for all material types and branches).

1-4-4 Open a second session and check your settings by displaying material master record T-RD2##.

Reverse your changes from exercise 1-4-3 for the rest of the exercises.

1-5 Default settings for industries and organizational levelsTo make entering data easier, define default data for the branch (chemicals) and organizational level (1100 as the default plant and source plant) before you create the material master records. Define the default settings in a way that the industry and organizational fields only appear when you need them.

1-6 Creating material master records

1-6-1 Raw materials

Create the following material with the material type raw material by copying:

Material Material type

Copy from

T-RD1## Rawmaterials

T-RD100

In the Select View(s) dialog box, select all of the views except Warehouse management 1 and 2.

On the Basic Data 1 screen, check the following description for your material:

Material Material description

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T-RD1## Sulfuric acid

Go through all of the data screens and save the material master record when you reach the last data screen.

The material mentioned above is a raw material that will be needed to produce the product.

1-6-2 Finished product

Create material T-FD1## with the material type finished product by copying material T-FD100:

Material Material type Copy from

T-FD1## Finished product T-FD100

In the Select View(s) dialog box, select all of the views.

On the Basic Data 1 screen, check the following description for your finished product:

Material Material description

T-FD1## Detergent, group ##

Go through all of the screens and save the material master record when you reach the last data screen.

In this course, you will create a master recipe for the production of finished product T-FD1##.

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1-7 Displaying the material master record:

Display the following materials.

What type of materials are they and which material categories are assigned to them?

Material Industry sector

Material type

Material description

T-RD2##

T-RD3##

T-RD4##

T-RD5##

These materials will be used for the production of the finished product T-FD1## along with the raw material in exercise 1-6-1.

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4.21Solutions

Unit: Materials

Topic: Material Master Records

1-1 Settings for material types

SAP standard menu Tools AcceleratedSAP Customizing Project Management [SAP Reference-IMG] Logistics - General Material Master Basic Settings Material Types Define Attributes of Material Types

Display

1-1-1 Solution table

Double-click the material type.



RawMaterials

Material type FERT HALB ROH

Are internal orders allowed? Yes Yes No

Are external orders allowed? Allowed with warning

Yes Yes

Which of the following fields are selected in the User departments area?

Sales? Yes Yes No

Costing? Yes Yes Yes

Purchasing? Yes Yes Yes

MRP? Yes Yes Yes

Work scheduling? Yes Yes No

Which price control is set? Standard price Standard price Moving average price/periodic

unit price

Does a quantity update take place for the material type?

By valuation area

In all valuation areas

In all valuation areas

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1-1-2 What does the External no. assignment w/o check indicator specify?

Choose the F1 help for the field.

If the indicator is set, the material number can be entered manually and it is not compared with the number range for the material type. If the indicator is not set, the number entered is compared with the external number range if external numbers are allowed for this material type.

1-1-3 What does the With qty structure indicator specify?

Choose the F1 help for the field.

This field is used to specify whether product costing is carried out with or without a quantity structure (BOM and routing).

1-2 Creating a new material type

Tools AcceleratedSAP Customizing Project Management SAP Reference IMG Logistics - General Material Master Basic Settings Material Types Define Attributes of Material Types Copy as ... PI## ‚PI Gruppe ##’

Make the settings as described.

1-3 Setting the required fields

You first determine the number of the field selection group.

Tools AcceleratedSAP Customizing Project Management SAP Reference IMG Logistics - General Material Master Field Selection Assign Fields to Field Selection Groups

1-3-1 Field selection groups

Go to Position cursor

MARA-BISMT: 11MARA-MSTAE: 155

1-3-2 Detail screen for field names: Since the Propose field content indicator is set, the contents of the fields are copied when they are created.

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1-3-3 Tools AcceleratedSAP Customizing Project Management SAP Reference IMG Logistics - General Material Master Field Selection Maintain Field Selection for Data Screens

Enter field selection group 11 in the appropriate field and choose Enter. No other fields belong to field selection group 11. Repeat the procedure for field selection group 155. The fields MARA-MSTAE and MARA-MSTDE belong to group 155.

Choose Details.

1-3-4 Copy field reference Z## and specify that these fields are required fields.Copy the field reference for the semi-finished product HALB.Select the line HALB and copy it to Z## (Edit Copy as). Call up the field groups 11 and 155 in the field reference Z## you just copied. Change the field option to a required entry.

Save your settings.

1-3-5 Assign field reference Z## to your material type PI##.

Tools AcceleratedSAP Customizing Project Management SAP Reference IMG Logistics - General Material Master Basic Settings Material Types Define Attributes of Material Types

Select material type PI## and choose Goto Details.

Field reference Z##” instead of “Halb”.

Save your settings.

1-4 Copy the screen sequence 21 by choosing Edit Copy as....

SAP standard menu Tools AcceleratedSAP Customizing Project Management [SAP Reference-IMG] Logistics - General Material Master Configuring the Material Master-> Define Structure of Data Screens for Each Screen Sequence

Save the screen sequence.

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1-4-1 Select your screen sequence and double-click the entry Data screen in the dialog structure.Select data screen 08 “Basic Data 2” and double-click the entry Subscreens in the dialog structure. Choose View data screen. Notice the simulation of the logical screen. Choose Cancel. Select the subscreen with Screen number 2010 and choose View subscreen. You now see the Environment screen module .

Go back to the Change view "data screen": Overview screen by double-clicking Data screens in the dialog structure. Select data screen 07 “Basic data 1” and double-click the entry Subscreens in the dialog structure. Add the screen module (subscreen) “Environment” to this data screen by overwriting screen number 0001 (=empty screen module) with the number 2010. Choose View data screen. The Environment screen module is now copied to the “Basic data 1“ data screen. Choose Cancel. Double-click the entry data screens in the dialog structure. Select data screen 08 “basic data“ and choose Edit -> Delete. Change the screen description and the alternative screen description of data screen 07 to “Basic data“. Save your changes.

1-4-2 SAP standard menu Tools AcceleratedSAP Customizing Project Management [SAP Reference-IMG] Logistics - General Material Master Configuring the Material Master-> Maintain Order of Main and Additional Screens. Select the screen sequence and choose Goto->Details. For the data screens MRP 1-4, Work scheduling and General plant data/storage, enter ascending numbers in this sequence that are between the numbers of the data screens Basic data and Classification in the column for sequential numbers. Example :

MRP 1 Current No.: 11MRP 2 Current No.: 12MRP 3 Current No.: 13 etc.

Choose Sort main screens. The screens are put in a new order. Save your changes.

1-4-3 SAP standard menu Tools AcceleratedSAP Customizing Project Management [SAP Reference-IMG] Logistics - General Material Master Configuring the Material Master-> Assign Screen Sequence to User/Material Type/Transaction/Industry Sector

Double-click User screen reference in the dialog structure and then New entries. Enter your user name PI-## in the first column and your screen sequence number Y# or Z# in the second column.Save your entries.

It is not necessary to define the screen sequence control before the user. It is only a selection criteria for controlling the screen sequence. The assignment of one entry to different users allows you to group the users.

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Double-click Screen sequence control in the dialog structure and then New entries. Enter the following and then save:

SRef:trans. SRef:user SRef: matl type SRef: industry SSq

01 Y# or. Z# * * Y# or Z#

1-4-4 Testing the settings:Open a second session:SAP standard menu Logistics Production – Process Master Data Material Master Material Display Display currentDisplay material master T-RD2##. Notice the sequence of the views in view selection.Choose the Basic data view. The Environment screen module appears.

Reversing changes made in exercise 1-4-3:

In the Change View Screen Sequence Control: Overview view, delete your entry in the Control Screen Sequence table. Choose Edit Delete. Save after deleting and check your settings by displaying material master T-RD2## again.

1-5 Default settings for industry sectors and organizational levels

SAP standard menu Logistics Production - Process Master Data Material Master Material Create general Immediately

Enter a material type, such as "raw material" and a branch such as "chemical industry".

Choose Defaults Industry sector. Choose "Chemical industry". Select the Hide industry sector on initial screen indicator.

Choose Defaults Organizational levels. Enter plant 1100, source plant 1100. Select the Org.levels/profiles only on request indicator.

You can also maintain the user settings in Customizing by choosing: SAP standard menu Tools AcceleratedSAP Customizing Project Management [SAP Reference-IMG] Logistics - General Material Master Configuring the Material Master-> Maintain User Settings

1-6 Creating material master records

1-6-1 Raw materials

Material Master : Material -> Create (general) -> Immediately

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Select all in the view selection.

1-6-2 Finished product

Material Master / Material -> Create (general) -> Immediately

Select all in the view selection.

1-7 Displaying the material master record:

Material Industry sector

Material type Material description

T-RD2## C ROH Lauryl Alcohol

T-RD3## C PIPE Water

T-RD4## C ROH 1-Butanol

T-RD5## C ROH Sodium hydroxide

Material master menu / Material -> Display -> Display Current

Choose Information on material.

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Creating characteristics and classes in the R/3 classification system

Classifying objects

Classifying objects for process manufacturing

Contents:


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R/3 Classification System: Unit Objectives

Describe the advantages of classification

Create classes, characteristics, and objects

Classify objects

Define the functions of the class types

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PP-PI Overview


Introduction

Materials

Batches



Production Version






1111

22

33

11

44

66

77

88

99

1010

1212

1313

1414

1515



55 R/3 Classification System

Overview Diagram 5

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R/3 Classification System: Business Scenario

Classification is required in your company for the selection of materials and resources for production.

You are responsible for the classification of raw materials and finished products.

You will define a class with the appropriate characteristics to select a suitable reaction vessel for detergent production.

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Value AssignmentValue AssignmentValue Assignment

Classification = Object Assignment + Value AssignmentClassification = Object Assignment + Value Assignment

Material Class T-CL100Material Class TMaterial Class T--CL100CL100

Classification

AssignmentAssignment

Va

lues

Va

lues

BatchCH-01

Classification

Acids: Ph 7Solids: 68 %Freezing Point: 3.20°F

Acids: Ph 7Solids: 68 %Freezing Point: 3.20°F

Acids:Solids:Freezing Point:

Acids:Solids:Freezing Point:

In classification, you assign objects to classes and use the characteristics of the class to describe the objects.

You can then use the classification system to search for the objects. You can use the settings in characteristics maintenance to specify, for example, that entries are required

or default values are used in classification.

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Describe objects using characteristics

Group similar objects in classes

An object exists

Similar objects exist

No objects exist

You can use the find object function to determine whether:

Classification in the R/3 System

Classification enables you to:

The classification system is a cross-application basic function. The purpose of a classification system is to describe objects using characteristics and to group or classify

similar objects based on a criteria that is defined. You can search for objects using the classes and the characteristics defined for the classes. In this way,

you ensure that objects that are similar or identical regarding their characteristics can be found as soon as possible.

Any basic data elements of the R/3 System can be classified (materials, batches, recipes, operations, resources, documents, ...)

Classes can be structured in single-level or multi-level class hierarchies.

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A class is used to groupobjects that have identical or

similar attributes.

An object is a classifiable unit (such as resource, material,

batch, and so on).

A characteristic value is a value assigned to a characteristic

of an object (such as 1000 l, 130 CP).

A characteristic is used to storeinformation on the attributes of anobject (such as volume, viscosity).

CharacteristicCharacteristic Characteristic ValueCharacteristic Value

ClassClass ObjectObject


Characteristics that are defined individually are assigned to classes. A characteristic describes a detail of the classified object. After assigning an object to a class, the object characteristics can be assigned values. Objects can be assigned to several classes.

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Class 270 (Oils)

Class Type 001 (Material Classes)

Oil-001

Viscosity120 cP

Object

CharacteristicChar. Value

Class

Class Types

Oil-002 Oil-003

Viscosity130 cP

Viscosity140 cP

R/3 Classification System: Example

You can search for objects using the classification system. Two steps are required to find a certain object:

Find the class in which the object is classifiedSearch for the object in the class

During the search, the characteristics are used as search criteria. They are assigned values, and these values are compared with the values of the objects that are in the class.

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Class types

Objects

ResourceMaterial Operation/recipe

001001Mat. classesMat. classes

019019Work ctr cl.Work ctr cl.

023023BatchesBatches

Class Types

Classes are always assigned to a class type. A class type is a top-level unit of control for classes. The class type is used to define, for example:

Which objects can be classified in a classWhether objects of different object types can be classified in the same class

The standard system contains settings for some object types (for example, materials, vendors, documents, and so on) and class types so that you can begin creating a classification system for these objects immediately. You can also include other class types in the classification system.

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CreateCreatecharacteristicscharacteristics

Create class Create class for class typefor class type

Assign characteristicsto the class

Creating Classes

You can set up your own classification system in the following way: Define the properties of an object:

You use characteristics to define the properties of an object. You create characteristics centrally in the R/3 System.

Create classesYou need classes to classify objects. These classes must first be created. Characteristics are assigned to the classes.

Up to 999 characteristics can be assigned to a class. The system checks the characteristic values by comparing them to the allowed value range.

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CreateCreatecharacteristicscharacteristics

Create class Create class for class typefor class type

Assign characteristicsto the class

Object

Specify char. values

Classifying Objects

The assignment of objects:After the classes required for classification have been created, the objects of these classes can be assigned. The objects are described using the characteristics contained in the classes. In this way, the data required to use the classification system is available. The system can then be used to find objects with specific properties.

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Materials / Batches

Resources

Operations: Master Recipe

BOM Items

Class Type "Batch"Class Type "Batch"

Class Type "Work Center Class"'Class Type "Work Center Class"'

Classifying Objects for Process Manufacturing

In PP-PI, different objects can be classified, for example, within a master recipe. In this way, resources (for resource selection which takes place later) as well individual operations of a recipe, for example, can be assigned to a class.

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Class type: 019 "Work center class"

Characteristics

Coating GraphiteVolume 350 l

Characteristics

Coating PVCVolum 250 l

Class:Class: Reaction vesselReaction vessel

Object:

Reaction vesselRE-01

Characteristics

Coating EnamelVolume 300 l

Characteristics

U/min 200°CVolume 250 l

HV-02

Characteristics


Class: Heating vessel

Object:

Heating vessel

Characteristics

Max. temp. 300°CVolume 200 l

. . .

Characteristics


MV-02

Characteristics


Class: Mixing vessel

Object:

Mixing vesselRK-01

Characteristics

U/min 150Volume 300 l

. . .

. . .

. . .MV-03

HV-03RE-02

RE-03

Example : Classification of Resources

Classes are always assigned to a class type. A class type is a top-level unit of control for classes. The class type is used to define, for example:

Which objects can be classified in a classWhether objects of different object types (such as materials and batches) can be classified in the same class

There are predefined class types in the standard system such as the class type work center class, for classifying resources, or class type batch, for classifying materials and batches.

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R/3 Classification System: Summary

Creating a class:

Create characteristics

Create class for class type

Assign characteristics to the class

Any objects in the R/3 System, such as resources, operations, or MRP components, can be assigned to a class.

The top-level class type for the class controls, for example, which objects can be classified in the class and whether a multi-classification is allowed.

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5.15Exercises

Unit: R/3 Classification System

Topic: Characteristics and Classes


Display and create characteristics

Display and create classes

Classification is required in the company for the selection of materials and resources for production.

You are responsible for the classification of raw materials and finished products.

Furthermore, you are to define a class with the appropriate characteristics to select a suitable reaction vessel for detergent production.

1-1 R/3 classification system

1-1-1 Display the characteristics M100 and M200

Logistics -> Central functions -> Classification Master Data -> Characteristics. Choose Display.

Write down the description and formatting details for these characteristics.

Characteristic Description Data type Unit of measurement

M100

M200

Which status do the characteristics have?

________________

What value assignments have been defined for the characteristics?

________________

Is a value assignment for a classified object required?

________________

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Are interval values allowed for the value assignment?

________________

Are you allowed to enter negative values?

________________

To which class types is the usage of the characteristics restricted?

Restrictions tab

________________

________________

________________

Within which value range are you allowed to assign a value to a characteristic?

Values tab

Characteristic Allowed values

M100

M200

Are you allowed to assign values that have not been defined as allowed values?

________________

Display the indicators for one of the characteristics on the Additional data tab.

Additional data tab

Use the F1 help to find out more about the functions of these indicators.

1-1-2 Display the class 023_14 of the class type 023 Batch.

Which description does this class have?

_______________

Which status does this class have?

________________

Which characteristics are assigned to this class?

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Characteristics tab

________________

________________

During the course, the class 023_14 will be used for classification of the raw materials used in the production.

1-1-3 Creating characteristics

In this exercise, you will first create the characteristics M3## and M6## in the R/3 classification system. These characteristics will then serve as a basis for class REAC_## that is also to be created for reaction vessels.

1-1-3-1 Create characteristic M3##:

Description Surface coating

Data type Character format

No. of char. 1

Value assignment Single-value

A value assignment for the characteristic is required.

Restrict the possible characteristic values to the following:

Characteristic value Description

G Glass coated

P Polyethylene coated

S Stainless steel

Restrict the usage of the characteristics to the class type 019 Work center class.

Save characteristic M3##.

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1-1-3-2 Create characteristic M6##:

Description Revolutions per minute, group ##

Data type Numeric format

No. of char. 3

Decimal places 0

Unit No entry

Value assignment Multiple values

A value assignment for the characteristic is not required.

Interval values are allowed.

Enter a possible value range of 0 – 500.

Specify that the allowed values are displayed during value assignment.

Restrict the usage of the characteristics to the class type 019 Work center class.

Save the characteristic M6##.

1-1-4 Creating a class

Create the class REAC_## of the class type 019 Work center class.

Enter "Reaction vessel" as the description and assign the characteristics M3## and M6##.

Save your class.

During the course, the class REAC_## will be used for the classification of resources (reaction vessel). A resource selection based on previously defined characteristic values will follow at a later time.

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5.16Solutions

Unit: R/3 Classification System

Topic: Characteristics and Classes

1-1 R/3 Classification System

1-1-1 Display the characteristics M100 and M200.

Logistics -> Central Functions -> Classification System Master Data -> Characteristics (Display)

Characteristic

Description Data type Unit of measureme

nt

M100 Concentration Numeric format %

M200 Density Numeric format g/ccm

Which status do the characteristics have?

Released

What value assignments have been defined for the characteristics?

Single-value

Is a value assignment for a classified object required?

no

Are interval values allowed for the value assignment?

yes

Are you allowed to enter negative values?

no

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To which class types is the usage of the characteristics restricted?

Choose the Restrictions tab.

001 = Material class

022 = Batch (at plant level)

023 = Batch (at client or material level)

Within which value range are you allowed to assign a value to a characteristic?

Values tab

Characteristic Allowed values

M100 2.0 - 98.0 %

M200 0.5000 -2.0000 g/ccm

Are you allowed to assign values that have not been defined as allowed values?

No

Additional data tab

The indicators are listed under "Procedure for value assignment" and "User entries handling".

1-1-2 Display the class 023_14 of class type 023 Batch.

Logistics -> Central Functions -> Classification System Master Data -> Class Management (Display)

Which description does this class have?

Detergent production

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Which status does this class have?

Released

Which characteristics are assigned to this class?

Characteristics tab

M100 Concentration

M200 Density

1-1-3 Creating characteristics

Logistics -> Central Functions -> Classification System Master Data -> Characteristics Management (Create)

same as part 1-1-1

1-1-4 Creating a class

Logistics -> Central Functions -> Classification System Master Data -> Class Management (Create)

same as part 1-1-2

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6

SAP AG 1999

Batches

Material and Batch

Batch Management in the Logistics Process

Levels of Uniqueness of a Batch

Classification of a Material and a Batch - Characteristic Inheritance

Batch-Specific Material Unit of Measure

Active Ingredient / Product Quantity Management

Contents:

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SAP AG 1999

Batches : Unit Objectives

Define the term "batch"

Describe how you can use batches in logistics

Use the levels of uniqueness for batches

Have batches inherit the characteristics of the top-level materials

Make basic settings for active ingredient management


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Overview Diagram 6

PP-PI Overview


Introduction

Materials




Production Version






1111

22

33

11

44

55

77

88

99

1010

1212

1313

1414

1515



66 Batches

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Batches : Business Scenario

Since the production is to be handled in batches, you will define, as the person responsible for the basic data, the finished product as subject to be handled in batches.

A raw material is also to be handled in batches.You will define a batch master record for this raw material.

You will then be able to make a posting of stock for the raw material.

You will also check the settings for active ingredient management.

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Material and Batch

Material Y-300Yellow paint

Batch mgmt reqmt

Batch B1Batch B1

Origin:

Process order 60000114

Specifications:

Origin:


Specifications:

Origin:


Specifications:

Viscosity: 170 -178 cP95.0 - 98 %

580 -620 nm Covering property: Wavelength:

Viscosity: 175 cP97.0 %

589 nm Covering prop.: Wavelength:





Batch C2Batch C2 Batch C3Batch C3

In the R/3 System, batch master records depend on the corresponding material master records. Batches are created for a material.

In general, the data of a material master record is valid for all batches assigned to it. In contrast, a batch master record contains data that uniquely identifies a batch and characterizes it as a non-reproducible unit.

If a material is to be produced in batches and is subject to inventory management, you must set the Batch management indicator in one of the material master views of Purchasing, Work Scheduling, or Storage.

You either create a batch master record directly during master data maintenance or the system creates it in the background during the first goods movement.

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Batch Management in the Logistics Process

Ware-house

Process/productionorder

Ware-house

Salesorder

Warehouse mgmt

A A

A

KMTKMT

Batch Batch assignmentassignment

Batch determination

Batch Batch assignmentassignment

Purchaseorder

ProcurementProcurement ProductionProduction SalesSales

Batch determination

A

B

A

B

Warehouse mgmt

R/3 batch management is used in all areas of logistics. A batch can be followed through the whole logistics chain, from the entry of the raw materials to the production of the finished product, and all the way to sales and delivery to the customer.

You can assign a batch to a material at various points in the logistics process by creating a batch master record. For example, if the subset of a material that is subject to being handled in batches leaves a production process with certain specifications, it is posted to stock with a batch number and can then be clearly identified.

If you need a batch with certain specifications in the logistics process, you can find suitable batches from the system in the stock using the batch determination function. In the production area, batch determination is carried out in a process order to find and withdraw suitable material components for the product to be produced.

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Levels of Uniqueness of a Batch

In combination with a plant and material

Unique batch number

Material Y-300 Material P-300

Plant 1 Plant 2 Plant 1 Plant 2

Batch 1 Batch 1 Batch 1 Batch 1

At client level Material Y-300 Material P-300

Batch 1 Batch 2 Batch 1

In combination with a material number

Material Y-300 Material P-300

Plant 1 Plant 2 Plant 1 Plant 2

Batch 1 Batch 1

A material master record is identified by an alphanumeric material number. This material number is unique at the client level.

A batch master record is identified by an alphanumeric batch number. You can choose the level at which you want the batch number to be unique in accordance with the structure of your plant and company and your operational requirements.

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Changing Batch Levels

Material levelMaterial level

Plant levelPlant level

Client levelClient level

You can select the validity of the batch in Customizing. Three batch levels are available. The default setting in the standard system is the plant level.

You can change to a higher level at any time. However, if you want to change to a lower level, the system only lets you change from the client level to the material level. You cannot change to the plant level. This is due to the organization of the batch data, which must be converted each time you change the batch level.

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Converting Batch Numbers

Batch

C1

C4

B2

B3

Material

4712

Batch

C3

C4

B1

B2

Material

4712

Plant 01 Plant 02C1

B3

C4

B2

C3

B1

Plant level

Material level

Plant level

Material level

Batch

Material

4712

C1 C3 C4 B1 B2 B3

Reorganization program

If the batch number was unique at the plant level up to now, and you want to change the validity so that it is unique only at the material level, you must convert the batch numbers when you make this change.

Up to now, you could issue the same batch number for one material number in each plant. The batches did not need to be identical, since they were completely independent of each other. In this example, we assume that the batch specifications are completely different.

When converting existing batch data, the system checks whether identical batch numbers exist. If all batch numbers are unique at the new level (that is, the material level), the batch number can be converted directly. If they are not unique, the system writes a log containing all batch numbers that cannot be converted. You have to decide which batch numbers remain valid and which have to be posted to new batches together with their stock. If you want the system to delete batches, you must set the deletion flag and start a batch reorganization run.

You can use the conversion tool to display the current state of conversion. The system repeats the checks again and again to find out if the existing batch numbers are unique at the new level. Use the test mode. If the numbers are unique, you can carry out conversion.

At the new batch level, the batch number is unique for each material and is no longer additionally distinguished by the plant.

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SAP AG 1999

Viscosity: 170 -178 cP95.0 - 98 %

580 -620 nm Covering property: Wavelength:


589 nm Covering property: Wavelength:

Classification of a Material and a Batch -Characteristic Inheritance

CharacteristicsCharacteristics

Class type "Batch"Class type "Batch"

Class 023_08Color

Material Y-300Yellow color Batch B1

Char.

Inheritance

Viscosity:Viscosity: Covering property: Wavelength:

100 100 -- 200 cP200 cP0 0 -- 100 %100 %

400 400 -- 800 nm800 nm

When defining the specifications for batch master records, the higher-level material master records are assigned to classes belonging to class type batch. In these classes, all material and batch attributes are stored as characteristics.

When you create a batch for a material, the batch is automatically assigned to the same class of class type batch used to classify the material. This ensures that the same characteristics are used for the material and the batch. In the R/3 System, this is called characteristic inheritance.

Class type batch specifies a hierarchical relationship between the object types "material" and "batch". The batch inherits the material's characteristics. The specifications for the individual batches are stored as characteristic values.

You can define value ranges or fixed values for a characteristic of a class. These specify a maximum value range that applies to all objects assigned to this class, in this case materials and batches.

In the material master record, you can further restrict the values preset by the characteristics. These restrictions are inherited by the batch of the material. You can then only assign values to the characteristics of the batch that lie within the range specified for the material.

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CharacteristicsCharacteristics

Class X

Creating Classes for Batches I

Create a class.Use the class type for batches.

Classification system

Assign characteristics to the class.

Create characteristics.

Class Type "Batch"

ViscosityViscosity ColorColor Epoxy no.Epoxy no. Volatile portionVolatile portion 0.00 0.00 -- 0.500.50

5000 5000 -- 12000120000 0 -- 5523 23 -- 2525

ViscosityViscosity ColorColor Epoxy no.Epoxy no. Volatile portionVolatile portion

Class X

The classification system must be set up such that the specifications of a material and its batches can be stored as classification data.

First, you define the properties that you want to specify the material and the batches.These properties are stored in the classification system as characteristics.

You now create the classes that you want to use for the material and the batches. You can create a selection of various classes for this purpose. Later, you can only assign one class to the material and the batch. You thus do not set up multiple classification.

You have to assign class type 022 or 023, as these have been set up in the standard system specifically for batches. The applicable class type depends on the batch level you have selected.If you have specified plant level as the validity range of the batch in Customizing, you must select class type 022 in the standard system. Otherwise, class type 023 is valid. The system automatically suggests the correct class type.

In the last step, you assign the characteristics to the class. When doing so, you can restrict the value ranges even further.

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SAP AG 1999

Materials management

MaterialMaterialEpoxy resin YEpoxy resin Y

Creating Classes for Batches II

Classify your material with the batch class.

BatchBatchEpoxy resin Y1Epoxy resin Y1

Post a batch to the material.

Assign allowed characteristicvalues to your batch.

Class X

Class Type "Batch"

ViscosityViscosity ColorColor Epoxy no.Epoxy no. Volatile portionVolatile portion 0.00 0.00 -- 0.500.50

5000 5000 -- 800080000 0 -- 5523 23 -- 2525

ViscosityViscosity ColorColor Epoxy no.Epoxy no. Volatile portionVolatile portion 0.300.30

725072501 1 -- 3323 23 -- 2525

In Materials Management, you create the material master record and batch master record. You must classify the material to be able to use the entire functionality of batch management.You assign the batch class in the classification view of the material master.You can restrict all value ranges of batch characteristics.

When you create a batch for this material, the system automatically copies the classification data of the material and proposes the value ranges of the characteristics.

The system checks whether the characteristic values you entered lie within the value range if you have defined the characteristics accordingly. For the system to be able to do so, you may not set the Additional values indicator.

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6.13

SAP AG 1999

The Batch Where-Used List at Several Production Levels

Top down

Bottom up

F=Finished prod. H=Semi-fin. prod. R=Raw material

Customer A Customer B Customer C

F1F1 F2F2

H2H2

Vendor

R1R1 R2R2

H1H1

Customer order Customer order Customer order

Production order Production orderProduction order

Production order Production order

Purchaseorder

The batch where-used list follows the path of a batch using inventory management. Each batch receives its document journal from the first posting to stock to the withdrawal from stock. Additionally, each link between batches is documented at every production level all the way to the customer order and the batch split.

The path of a batch is only registered when an inventory posting has taken place. The numbers of the reference documents, such as the production order and the customer order, are recorded along with the material document.

The display variations "top down" and "bottom up" describe the view direction using the "family tree" of the batch.

The batch where-used list can also be processed graphically.

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SAP AG 1999

Batch-Specific Material Unit of Measure

An alternative unit of measure of a material, for which you can define the conversion ratio into the base unit of measure on a batch-specific basis.

Batch-specific material units of measure are:

Proportion unit

Product unit

Proportion and product units for batch-specific materials can be used in all processes in the logistics chain.

BatchBatch--specific material unitspecific material unit

Proportion unit:Unit of measure in which you can enter proportions of the base unit of a material. The total or physical quantity can consist of several proportions.

Product unitUnit of measure which describes the total quantity of a material as an alternative to the base unit of measure.

You use batch-specific units of measure when the ratio for conversion from the unit of measure into the base unit of measure can differ from batch to batch.

While the conversion ratio for the alternative units of measure is fixed in the base unit of measure in the material, for the proportion unit and the product unit you define the following:

-The planned conversion ratio in the material-The actual conversion ratio in the batch

As long as the batch is not known, the system uses the planned conversion ratio from the material when converting to the base quantity. As soon as the batch is known, the system uses the actual conversion ratio from the batch.

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6.15

SAP AG 1999

AA

BatchBatch

Contains 0.7 liters active

ingredient / liter

Melting point at 45° C

Expires on 12/31/99

Batch-specific unit 1 PC equals 110 KG

Batch-Specific Units of Measure as an Attribute of a Batch

The specification contains the description of the batch. It may also contain measured values and quality characteristics, plus details concerning the usability of the batch and whether it is locked. Important date specifications may also be included, such as the expiration date, the last goods receipt date, and so on.

The active ingredient proportion is one of the criteria that should be used to differentiate between batches of the same material. For this reason it is integrated into the batch specification.

Likewise, the conversion factor between alternative units of measure and base units of measure in a batch forms a characteristic, which can be valuated differently from batch to batch.

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SAP AG 1999

Batch-Specific Unit of Measure

Classification

Batch ManagementBatch Management

Integration of Batch-Specific Units of Measure

In the R/3 System, batch-specific units of measure (active ingredient management and product units) are handled in Batch Management.

The active ingredient potency of a batch is stored in the batch's specification along with the batch-specific ratio between the alternative unit of measure and the base unit of measure.

Batch Management uses those features found in the classification system. The characteristic values in the batch classification form the specification.

To use batch-specific units of measure, you must have Batch Management set up, the class system must be in use, and the material concerned must be able to be handled in batches.

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SAP AG 2001

Physical Quantity and Active Ingredient Quantity

Withdraw 45

liters of

alcohol!

50% a.i. 90% a.i.

92% a.i.

Full quantity: 500 l Full quantity: 500 l

Full quantity: 500 l

If active ingredients are not suitable for storage on their own, they are stored together with carrier materials. A combination of a carrier material and an active ingredient is called a physical quantity or a weighed quantity. The terms mixed quantity and telquel quantity are also common.

The situation is similar if materials contain impurities of varying degrees. The amount of active ingredient in a material is its active ingredient quantity. The potency (of active ingredient) varies within a material to a certain degree. A material can contain more than one different active ingredient.

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SAP AG 1999

The Central Unit of Measure for Active Ingredients

Sales

PurchasingA

BBC

B

Inventory Management

ProportionUnit

BOM

The proportion unit can be seen as a core element which is found throughout the applications and is used to reproduce the active ingredient potency of a material.

The conversion between the proportion unit and the base unit of measure is continuously maintained in the background and can be displayed by each of the respective applications.

The physical quantity is measured in base units of measure, whereas the active ingredient is measured in proportion units.

In Logistics you may enter the active ingredient quantity instead of the physical quantity.

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SAP AG 2001

Relation of Units of Measure

Proportion unit

Base unit of measure

=

Ratio

Liter of active ingredient per

liter

LIL

Liter of fruitLF

LiterL

The base unit of measure is the leading unit of measure for a material containing active ingredients. You post the materials in this unit. If an entry is made in proportion units, the system converts this to base units of measure before posting.

The proportion unit is based on the active ingredient. If a material contains more than one active ingredient, separate proportion units must be defined for each active ingredient so that they can be clearly distinguished.

You store a ratio to convert quantities between the proportion unit and the base unit of measure. This constitutes a separate unit of measurement.

In this example, the active ingredient "fruit" is measured in liters. LIL was defined as the proportion unit for the purpose of measuring an active ingredient.

The liters of fruit are based on one liter of the physical quantity. The ratio is recorded in the unit of measurement LIL.

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6.20

SAP AG 2001

Percentage and User-defined Calculation

Percentage calculation

User-defined calculation

Characteristicunits of measure

measure the active ingredient proportion in relation to the base

unit of measureLF / L

LIL

If the active ingredient proportion for a batch is known, the active ingredient quantity can be calculated from the base quantity. The relation between the potency of the active ingredient and the base quantity is stored in Customizing, and assigned to a characteristic unit of measurement.

If the relation is measured by percentage, the conversion is specified by definition. If the relation is user-defined, any formula can be stored that describes the relationship between the

proportion unit and base unit of measure.

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SAP AG 1999

Active Ingredient Characteristics

Which active ingredient ?

What is the ratio?

Data type: numeric

Value assignment: single-value

Fruit

LIL= (%)

LF

L

The characteristic description specifies the active ingredient on which the data is based and a unique assignment is made. For this reason, you should define one characteristic for each active ingredient.

The relationship between active ingredient potency and physical quantity must be entered as a unit of measurement when you create the characteristic.

The characteristic must be numerical and a single value.

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6.22

SAP AG 1999

Linking Master Data I

Batch classBatch class

Char. potency Char. potency (act.(act. ingredingred.).)

xy

Material

A

Batch 1A

Batch 2 A

Batch 3

Transfers specification

2

The potency of the active ingredient in a material forms part of its specification. If the potency is not constant, the different specified material inventories should be managed separately.

This is carried out by the Batch Management component of the R/3 System. Each batch bears its own characteristic values.

Batch specifications are stored in the classification system as characteristics. The ratio between the active ingredient and the base quantity is linked to a characteristic, and potency of active ingredient is stored as its characteristic value. In this way, the ratio becomes the characteristic unit of measurement.

The active ingredient characteristic contains the information about the active ingredient concerned and the ratio of the proportion of physical quantity to the base unit of measure.

The ratio between the potency of active ingredient and the physical quantity is stored in one batch characteristic and thus becomes part of the specification.

The material transfers the information to its batches.

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6.23

SAP AG 1999

Linking Master Data II

Batch class

Char. potency (act. ingred.)

Ratio LIL (%)

Unit of measurement

LIL (%)

View S = Subs.

LF <=> L

Material MasterMaterial Master

Active ingredient characteristics are assigned the special view 'S' within the batch class. Characteristics with this view are recognized when you maintain the material master. The information

for conversion between active ingredient and physical quantity is transferred to the material master.

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SAP AG 1999

Maintaining Units of Measurement in the Material Master

MaterialMaterial

View:Proportion/product unit

Characteristic Unit of meas. Prop. unitPlnd valueFruit

potency0.75 (75)

LFLIL (%)

X Prop. unit Y Base unit<=>

LF Liter75 100<=>

LF <=> L

After the classification view has been maintained, the system establishes whether any active ingredient characteristics are present.

You must complete the information in the Proportion/Product Unit view. The system requires a planned value for the active ingredient proportion.

The planned value specifies the expected mixing ratio between active ingredient and physical quantity in the characteristic unit of measurement.

If the actual proportion of active ingredient in a batch is not known for a particular business transaction, the system uses the planned value from the material master.The planned value for the conversion between active ingredient and physical quantity is transferred to the units of measure table automatically.

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6.25

SAP AG 1999

Batches : Unit Summary

A batch is a subset of a material with unique specifications.

The level of the uniqueness of a batch can be changed.

A batch that has been created for a material automatically belongs to the same class or has the same characteristics (characteristic inheritance).

A batch-specific material unit of measure is required for active ingredient management.

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6.26Exercises

Unit: Batches


Classify batches

Describe characteristic inheritance

Make settings for active ingredient management

Since the production is to take place in batches, define the finished product as a material to be handled in batches.

A raw material is also to be handled in batches. A batch master record is to be defined for this raw material.

Quantities are to be posted stock.

To be able to carry out active ingredient management at a later time, maintain the required settings.

1-1 Material to be handled in batches

Check whether the Batch management indicator is set for both the finished product T-FD1## and its raw material T-RD1##.

Select view(s): General Plant Data/storage 1

Organizational level:Plant 1100

Check whether the availability check for batches (CH) is set for the raw material T-RD1## in the MRP 3 view.

1-2 Classification of materials in the class type Batch

1-2-1 Classify your finished product T-FD1## in class 023_15 Detergent of class type 023 Batch.

Select view(s):Classification

Class type:023 “Batch”

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Assign the following characteristic values:

Density: 1.10 -1.20 g/ccm

Save your entry.

1-2-2 Classify your raw material T-RD1## (Sulfuric acid) in the class 023_14 Detergent of the class type 023 Batch.


Concentration 40 – 60 %

Density 1.30 -1.50 g/ccm

Save your entries.

1-3 Characteristic inheritance

1-3-1 Create the batch master record CH_1 for material T-RD1##.

To which class is the batch assigned?

________________

Classification tab

Within which value range can the characteristics be assigned values? Why?

______________________________

______________________________


Concentration 50 %

Density 1.39 g/ccm

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Save the batch master record.

1-3-2 Post a goods receipt of 500,000 L of batch CH_1 of material T-RD1## in storage location 0002 of plant 1100.

Use movement type 501.

Save the goods receipt and then check the stock for material T-RD1##.

1-3-3 Post another goods receipt (movement type 501) for batch CH_2 of material T-RD1## in storage location 0002 of plant 1100.

The system creates the batch master record in the background. Before posting the goods receipt, the system displays the characteristics of the new batch CH_2 for value assignment.


Concentration 40 %

Density 1.30 g/ccm

Post your goods receipt.

1-4 Settings for active ingredient managementYou have two materials, fruit premix T-RJ1## and lemon juice T-RJ2##, which contain the active ingredients fruit and acid. You want to change the logistic management for the materials. You want to be able to work with the material quantity and with the active ingredient quantity for the materials. Active ingredient management will allow you to do this. You need two batch-specific material units of measure (proportion units).

1-4-1 Check whether the required units of measure are maintained. What are the descriptions for the following units of measurement?

LF = _________________________________

LS = _________________________________

1-4-2 Make sure that the use of batch-specific units of measure is activated!

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1-4-3 To which base unit of measure are the batch-specific units of measure LF and LS referenced?

______________________________________________________

1-4-4 Notice the definition of the characteristic unit of measurement % for the proportion calculation.

Notice that in the case of proportion calculation in percent, the unit of measurement is defined in connection with the batch-specific units of measure and base units of measure.

Now notice the definition of the characteristic unit of measurement LIL.What are the batch-specific units of measure and the base unit of measure from which it is calculated?

LIL = __________________________________________________

1-4-5 Display the material master records for the materials fruit juice T-FJ1##, fruit premix T-RJ1##, and lemon juice T-RJ2##. Which data is maintained in their classification views?

Char. values: Char. values:

Material: Class: Fruit content Acid content

T-FJ1##

T-RJ1##

T-RJ2##

1-4-6 Check whether the organizational area S is maintained in the basic data and in the characteristics for the classes found under 1-4-5. Display the material master of the raw material T-RJ1##.

1-4-7 What are the characteristic names that belong to the characteristic descriptions fruit content and acid content?

Fruit content = ____________________________

Acid content = ____________________________

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1-4-8 Check whether the characteristics mentioned in 1-4-7 have the following settings:

The status is released.

The data type is numeric.

The value assignment is a single value and no negative values are allowed.

Which unit of measurement is maintained for these two characteristics?

_______________________________

1-4-9 What is the planned value defined for the fruit content on the Proportion/prod. unit tab in the additional data for material T-RJ1##?

___________________________________

Look at the Units of measure tab.

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6.27Solutions

Unit: Batches

1-1 Material to be handled in batches

Material -> Display -> Display current

Select view(s): General plant data/storage 1

Organizational levels: Plant 1100

1-2 Classification of materials in the class type Batch

1-2-1 Classify your finished product T-FD1## in class 023_15 Detergent of class type 023 Batch.

Material Change Immediately

Select view(s): Classification

Class type: 023 “Batch”

Assign characteristic values to class.

1-2-2 Classify your raw material T-RD1## (Sulfuric acid) in the class 023_14 Detergent of the class type 023 Batch.

same as in 1-2-1

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1-3 Characteristic inheritance

1-3-1 Create the batch master record CH_1 for material T-RD1##.

SAP standard menu ->Logistics->production-Process->Master Data/ Material master menu / Batch -> Create

Classification tab

To which class is the batch assigned?

023_14

Within which value range can the characteristics be assigned values? Why?

40 – 60 %

1.3 -1.5 g/ccm

The value range of the characteristics was defined in classification Part 1-2-2.

1-3-2 Goods receipt for batch created

Goods receipt:

SAP standard menu Logistics Materials Management Inventory Management Goods Movement Goods Receipt Other

Post goods receipt (save)

Check stock:

SAP Menu Logistics Production -Process Master Data Material Master Other Stock Overview

1-3-3 Goods receipt for batch not created

Goods receipt:

SAP Menu Logistics Materials Management Inventory Management Goods Movement Goods Receipt Other

Assign characteristic values to class.

Post goods receipt (save)

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1-4 Settings for active ingredient management:

1-4-1 Tools AcceleratedSAP Customizing Project Management SAP Reference IMG General Settings Check Units of Measurement. Choose Units of measurement (no dimension).

LF = L fruit LS = L acid (= L Säure)

1-4-2 Tools AcceleratedSAP Customizing Project Management SAP Reference IMG Logistics - General Batch Management Batch Specific Material Units of MeasureActivate Batch-Specific Material Units of Measure

1-4-3 Tools AcceleratedSAP Customizing Project Management SAP Reference IMG Logistics - General Batch Management Batch-Specific Material Unit of Measure Edit Batch-Specific Material Unit of Measure

Both batch-specific units of measure reference a liter.

1-4-4 Tools AcceleratedSAP Customizing Project Management SAP Reference IMG Logistics - General Batch Management Batch-Specific Material Unit of Measure Calculate Proportional Factors Define Percentage Calculation

Tools AcceleratedSAP Customizing Project Management SAP Reference IMG Logistics - General Batch Management Batch-Specific Material Units of Measure Calculate Proportional Factors Define Calculation of Proportion Quantity from Base Quantity

LIL = Liter of active ingredient / liter

1-4-5 SAP Standard Menu Logistics Production - Process Master Data Material Master Material Display Display Current

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Display the Classification view for each of the materials.

Char. values: Char. values:

Material: Class: Fruit content Acid content

T-FJ1## 023_20 35 – 40 % 2 – 2.2 %

T-RJ1## 023_20 80 – 100 % 3 – 5 %

T-RJ2## 023_21 - 40 – 80 %


Raw material T-RJ1##

View: Classification

Position cursor on the class entry and choose Environment Display master data

Basic data and Characteristics tabs

Both the class and the characteristics are maintained for application view S.



Position cursor on the class entry and choose Environment Display master data. Choose the Characteristics tab.

Fruit content = ______M800______________________

Acid content = ______M900_________________



Position cursor on the class entry and choose Environment Display master data

Characteristics tab

Double-click Characteristics.

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The characteristics M800 and M900 are both released, numeric, and single-value. Negative values are not allowed, and they are assigned to a class type batch. For both characteristics, the unit of measure % (percent) is maintained.

1-4-9 SAP standard menu Logistics Production - Process Master Data Material Master Material Display Display Current

Select Basic data view 1, choose Additional data, and then choose the Proportion/prod. unit tab.

The planned value for the fruit content is 85 %. The conversion ratio is entered on the Units of measure tab.

As long as the batch is not known, the system uses the planned conversion ratio from the material when converting to the base quantity. As soon as the batch is known, the system uses the actual conversion ratio from the batch.

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7

SAP AG 1999

General data for resources

Planning data

Data for capacity requirements planning

Costing data

Default capacity

Contents:


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7.2

SAP AG 1999

Make user-specific settings for the resource master record

Maintain general data for resources

Define formulas for resources

Create a default capacity

Prepare for the creation of a default resource


Resources: Customizing: Unit Objectives

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SAP AG 1999

PP-PI Overview

Materials

Introduction


Batches



Production Version

Master Recipes:Operations and Phases





1111

22

44

11

55

66

33

88

99

1010

1212

1313

1414

1515

1616


77 Resources: Customizing

Overview Diagram 7

Summary and Conclusion

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SAP AG 1999

Resources: Customizing: Business Scenario

Your company wants to reorganize the resources used for detergent production.

You are responsible for setting up and maintaining the resources. You will make preparations for the creation of a default resource in Customizing.

You will also define an available capacity for the corresponding capacity category.

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SAP AG 1999

Processing unit

Labor

Means of production and persons in the production process that have capacities assigned to them. Resources are subdivided into resource categories.

Resources

Waste disposal facility

Energy

Transport

Resources in the Company

Resources are the main planning instruments of production planning and control. The data you maintain for a resource is, for example, used for:

Scheduling process ordersCapacity requirements planningProduct and order costing

Resources are grouped in resource categories on the basis of their usage and function. You can define your own resource categories in Customizing.

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SAP AG 1999

Descrpts. Admin. data Classification Subsystems

Basic data Default values Capacities Scheduling Costing

General data

Standard value maintenance

Resource category

Person responsible

Plant

Resource Resource description

Resource Master Record

The data in the resource is used, for example, for:

Basic data

When creating a resource, you enter general basic data before you maintain specific data such as standard values, capacity data, or scheduling data.

Simplification of operation maintenance

Various default values can be maintained in the resource for operations.

Scheduling

Formulas for calculating operation duration can be maintained here.

Costing

Formulas for calculating the operation costs are maintained in the resource. In addition, a resource is assigned to a cost center.

Capacity requirements planning

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Formulas for calculating capacity requirements of an operation can be maintained here.

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7.7

SAP AG 1999

UsageUsage

ResourceResourcecategorycategory

Control of field and screen selectionControl of field and screen selection

Default resourceDefault resource

...

Basic data

Scheduling

Recipes

Routings for plant maintenance

...

Functions of the Resource Category

Resources are grouped in resource categories on the basis of their usage and function. You can define your own resource categories in Customizing. Resource categories have the following functions:

Each resource category is assigned one or more task list types in Customizing. A task list application groups one or more task list types. This assignment specifies the task list types for which a resource of a certain category can be used. Task list types are, for instance, master recipes, maintenance task lists, inspection plans. In PP-PI, the task list type "master recipes" is used.In Customizing, you can maintain a default resource for each resource category and plant. When you create a resource, the data maintained for the default resource is transferred to this resource as default values.In Customizing, you can define the screen sequence and field selection for resource maintenance for each resource category.

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SAP AG 1999

Modifiable field Input Req. Disp. Hide HiLi

Field 1

Field 2

Field 3

Field 5

Field 6

Field 7

Input in modifiable field (for all resource types)

Input in influencingfield (enter resource

type)

Field Selection

In Customizing for Resources, you can use field modification to influence the attributes of individual fields shown on the resource maintenance screens. You can specify how specific data fields are displayed. You have the following options for data fields:

Input field

Required input field

Display field

The field is hidden.

The field is highlighted.

You can decide whether the fields are to be modifiable or influencing for each screen group.

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7.9

SAP AG 1999

CapacityCapacity

VAR = DV *PHQU

BAQU

ClassA

$

Capacities

Capacity and Available Capacity

A capacity refers to the ability to perform a specific task.

A capacity refers to the ability to perform a specific task. Together with the available capacity and capacity loads collected for them, capacities are the central planning unit for capacity requirements planning.

You can assign any number of capacities of different capacity categories to one resource. You can maintain variable availability in time for each capacity. The available capacity is the ability of a capacity to perform a specific task in a certain period of time.

The available capacity is determined using work start and finish times, break times, rate of capacity utilization, and the number of individual capacities.

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7.10

SAP AG 1999

EnergyEnergyResourceResource

Processing unit 1Processing unit 1

Available capacityAvailable capacity

PooledPooledcapacitycapacity

Steam

MachineMachine

PersonnelPersonnel

ResourceResource

Processing unit 2Processing unit 2

Capacity Categories for a Resource

The ability of a resource to perform a specific task is limited in time. In the R/3 System, this limited availability is expressed by capacities.

Available capacities form the basis of scheduling for process orders and are required for capacity planning and shop floor control. Formulas are assigned to resources in order to calculate execution times and capacity requirements of operations.

You can assign any number of capacities of different capacity categories to one resource. However, per capacity category, you can only assign exactly one capacity.

A capacity category is a description that classifies capacities and can be defined by the user in Customizing. Capacity categories are, for example, machine capacities, labor capacities, and energy.

You create the available capacity that is to apply to only one specific resource as a resource capacity in the resource itself. Capacities that are used by several capacities, such as a common steam reservoir or the clean-out team, are created as pooled capacities and assigned to the resources.

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7.11

SAP AG 1999

Resource

Execution times

Capacity requirementsFormulas

Production costs

Formulas in the Resource

To calculate costs, execution times, and capacity requirements of phases carried out at a resource, enter a formula key that refers to a suitable formula on the corresponding screens of the resource.

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SAP AG 2001

General operationGeneral operationvaluesvalues

Formula constantFormula constant

Standard valuesStandard values

FormulaFormulaOperation qty

Base quantityTotal time = X

Base output

Res. outputX Duration

Operation quantity

Base quantity

Resource output

Duration

Base output

Example of a Formula

Formulas and formula parameters are defined in Customizing. Formula parameters that you can use include standard values, constants defined in the resource (for

example, resource output) as well as general operation values in master recipes or process orders (for example, operation quantity).

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7.13

SAP AG 1999

Define defaultDefine defaultresourceresource

Define Define formula formula

parameterparameter

Define Define standard standard value keyvalue key

Defineformula key

Define default capacity

Define area of Define area of responsibility responsibility

for cap. req. planningfor cap. req. planning

Create capacity categoryCreate capacity category

Define control keyDefine control key

Define task list usageDefine task list usage

Define person Define person responsible for resourcesresponsible for resources

Define resource categoryDefine resource category

1.21.2

1.31.3

44

33

2.12.1

2.22.2

2.32.3

2.42.4

1.11.1

Customizing a Default Resource

When you define a default resource in Customizing, you can maintain the following data:Capacity category, area of responsiblility for capacity requirements planning, default capacitiesResource category, person responsible for resourcesTask list usage, control keyFormula parameter, standard value key, formula key

The default resources defined in Customizing can be used as a basis for creating new resources in PP-PI. The previously defined default resources are copied when you go through the individual resource screens.

For each resource category, you can define exactly one default resource in Customizing.

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SAP AG 1999

Make settings for the field selection in the resource master record

Explain the structure and use of the formulas for the resource

Make the Customizing settings required to create a default resource

You are now able to:

Resources: Customizing: Unit Summary

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7.15Exercises

Unit: Resources - Customizing


Make general Customizing settings for resources

Define default capacities

Maintain formula parameters and formulas

Your company wants to reorganize the resources used for detergent production.

You are responsible for setting up and maintaining the resources. You are also responsible for creating a default resource in Customizing.

The available capacity for the resource must also be defined.

1-1 Resource data overview

To get a general overview of the screens and fields of a resource, look through those for resource T-IC1## for plant 1100. Write down the corresponding entries in the tables below.

Use F1 to find out more about the meaning and functions of individual data fields. Use F4 to have the possible entry values displayed for each data field.

1-1-1 Basic data tab

Description

Resource category

Person responsible

Task list usage

Standard value key

Parameters assigned

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1-1-2 Default values tab

Control key

Unit of measure of standard values

1-1-3 Capacities tab

Capacity category

Formula key

(Formula assigned for capacity requirements determination)

1-1-4 Scheduling tab

Capacity category

Duration of internal processing

(Formula assigned for calculating the phase duration)

1-1-5 Costing tab

Validity

Controlling area

Cost center

Activity type

Formula key

(Formula assigned for activity cost calculation)

From the resource menu, go to the SAP Library. Familiarize yourself with the information available on resources in the R/3 documentation.

Choose Default resource in the index to display information about the function of a default resource.

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1-2 General data and task list data for resources

In this exercise, you will become familiar with the most important Customizing settings for resources. IMG texts are available for the individual Customizing activities, which you can display if you need help making Customizing settings. Furthermore, you can use the F1 and F4 help.

Tools -> Accelerated SAP -> Customizing ->Project management -> SAP Reference IMG -> Production Planning for Process Industries -> Master Data -> Resource -> (..)

1-2-1 Defining a resource category

Define the resource category RE## "Processing unit gr##".

(...) -> Resource -> General Data -> Define Resource Category (Work Center Category)

Copy the field selection and the screen sequence of the existing resource category 0008.

Specify that change documents are to be written for the resources of the category RE##.

Assign the task list usage for recipes to resource category RE##.

1-2-2 Defining a person responsible for a resource

Define the person responsible R## "Person responsible for resource group##" for plant 1100.

(...) -> General Data -> Determine Person Responsible

1-2-3 Defining a task list usage

Define the task list usages O## "Recipe & Order group##" and C## "Recipe until release group##".

(...) -> General Data -> Define Task List Usage

Assign both task list usages to the task list type “Master recipe”.

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Indicate that a resource with a task list usage of C## can only be used until phase release, operation release, or order release.

1-2-4 Defining a control key

Define control key K1## "Cost., Sched., Cap. Grp.##" and K2## "Cost., Sched., Cap., QM Grp.##'".

(...) -> Resource -> Master Recipe -> Data for Operations and Phases -> Define Control Key

Set the Scheduling indicator, Det. Cap. Reqmnts indicator, and Cost indicator for both control keys.

For control key K2##, also set the Insp. char. required indicator.

Confirmations for the phases with this control key are possible, but not required.

1-2-5 Defining the field selection

Which field groups of the basic data screen group are defined as required entries for resource category 0008?

(...) -> Resource -> General Data -> Define Field Selection

_______________________ and _______________________

1-3 Data on capacity requirements planning


1-3-1 Creating capacity categories

Create the capacity category M## "Processing unit##" and P## "Personnel Group##".

(...) -> Capacity Requirements Planning -> Define Capacity Categories

Define capacity category P## as personnel capacity. Which function is made possible by setting the CapCatPers indicator?

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______________________________________________

______________________________________________

Save your entries.

1-3-2 Defining an area of responsibility for capacity requirements planning.

Define the responsible capacity requirements planner group C## "Cap. planner grp.##".

(...) -> Capacity Requirements Planning -> Determine Capacity Planner

1-3-3 Defining default capacities

Define default capacities for the capacity categories M## and P## in plant 1100.

(...) -> Capacity Requirements Planning -> Define Default Capacity

Define the following default values for both capacity categories:

Capacity planner group C##

Factory calendar ID 01

Base unit of measure H

Standard avail. capacity Start: 00:00:00

Finish: 24:00:00

Capacity utilization 100

No. of indiv. cap. 1

The capacity categories are to be relevant for finite scheduling. This means that the available capacity is taken into account during capacity requirements planning.

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1-4 Creating formulas for resources


1-4-1 Defining formula parameters

Define the following formula parameters:

(...) -> General Data -> Standard Value -> Define Parameters

Param Origin Short keyword and

keyword

Dim. Std value Std value unit.

Field name

DF## 2 Fixed time TIME H

DV## 2 Var. dur. TIME H

BAQU## Base quantity 1 BMSCH

PHQU## Phase qty 1 MGVRG

The parameters DF## and DV## are the standard values for the operation.

The parameters BAQU## and PHQU## are general operation values for the recipe or process order. The operation values are transferred to the formula parameters by way of their field names.

1-4-2 Defining a standard value key

Define the standard value key SK## "Fixed and variable time gr##" and assign the standard values DF## and DV## to it.

(...) -> General Data -> Standard Value -> Define Standard Value Keys

Also set the Generate indicator. You use this indicator to control whether a coding (ABAP command) is generated for a standard value key.

1-4-3 Defining formula keys

Define the following formulas:

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(...) -> Capacity Requirements Planning -> Resource (Work Center) Formulas -> Define Formulas for Resources (Work Centers)

or

(...) -> Costing -> Resource (Work Center) Formulas -> Define Formulas for Resource (Work Center)

Formula Description Formula definition

FIX## Fixed duration DF##

VAR## Duration, qty-dep. DV## * PHQU## / BAQU##

DUR## Total duration DF## +DV## * PHQU## / BAQU##

Be sure to put a space between each parameter and the adjacent operator. Set the Generate indicator for each one.

Also allow the use of the formula for costing, capacity requirements determination, and scheduling.

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7.16Solutions

Unit: Resources - Customizing

1-1 Resource data overview

Resources menu: Resource -> Display

1-1-1 Basic data tab

Description Mixing tank

Resource category 0008

Person responsible I##

Task list usage PI2

Standard value key SAP8

Parameters assigned Fixed time

1-1-2 Default values tab

Control key PI01

Unit of measure of standard values

min.

1-1-3 Capacities tab

Capacity category assigned 008

Formula key SAPL61

1-1-4 Scheduling tab

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Capacity category assigned 008

Formula key SAPL61

1-1-5 Costing tab

Validity 01.01.1998 – 12.31.9999

Controlling area 1000

Cost center 4271

Activity type 1420

Formula key SAPL61

1-2 General data and task list data for resources

1-2-1 to 1-2-4

Enter the Customizing settings as described in the exercise.

1-2-5 Defining the field selection

Position the cursor on the screen group Basic data. Choose Influencing and enter 0008 (resource category processing unit) as the influencing value. Choose Enter.

The following are required fields:

Usage and Person responsible

1-3 Data on capacity requirements planning

1-3-1 Creating capacity categories

(...) Resource -> Capacity requirements planning -> Define Capacity Categories

Define capacity category P## as a personnel capacity. Which function is made possible by setting the CapCatPers indicator?

You set this indicator to specify that persons can be assigned to this capacity category as single capacities.

1-3-2 to 1-3-3


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1-4 Creating formulas for resources

1-4-1 to 1-4-3


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8

SAP AG 1999

Resource management

Cost center assignment

Available capacity

Resource network

Classification

Evaluation options

Contents:


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8.2

SAP AG 1999

Create a default resource and resource master record

Maintain available capacities

Create resource networks

Define selection criteria for a system-aided resource selection

Execute evaluations


Resources: Functions: Unit Objectives

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8.3

SAP AG 1999

Overview Diagram 8

PP-PI Overview

Materials

Introduction


Batches



Production Version






1111

22

44

11

55

66

33

77

99

1010

1212

1313

1414

1515

1616


88 Resources: Functions Summary and Conclusion

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8.4

SAP AG 1999

You will create the master records for resources that are used for detergent production in your company.

You will also allow the resources to be selected just before production begins.

Resources: Functions: Business Scenario

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SAP AG 1999

Resource Data I

Default values

Basic data

Cost centerassignment

Name and description

Person responsible

Task list usage

Standard value key

Control key

Standard text key

Wage data

Cost center

Activity types

Formula key

Costing dataCosting data

Default valuesDefault valuesfor operations in for operations in master recipemaster recipe

General dataGeneral data

You can find resource-related data on several screens. This graphic shows some of the most important resource data.

On the Basic Data screen, you define a person or group of persons responsible for the maintenance of the master data of this resource. By defining the task list usage, you also specify the task list types (such as master recipe, equipment task list, or inspection plans) in which the resource can be used and whether the resource can be used in orders.

By entering a standard value key, a resource is assigned standard values for operations in master recipes or process orders to be executed at this resource. A standard value is a planned value used to carry out an operation, such as the execution time. Standard values are used in costing, scheduling, and capacity requirements planning to calculate costs, execution times, and capacity requirements.

You can enter default values for the operation to be executed at a resource. When you maintain the operations in the master recipe or process order, the system copies or references this information. You can, for instance, propose a control key. A control key specifies how an operation is to be processed from a business point of view.

By assigning a cost center to a resource, you link the resource to cost accounting and can now carry out product and order costing. You can define the specific output of a resource by assigning activity types which are defined for the cost center.

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8.6

SAP AG 1999

Capacity Available capacity

Formula key

Capacity dataCapacity data

Resource Data II

Assignments Persons

Positions

Qualifications

HR data /HR data /QualificationsQualifications

Scheduling Scheduling basis

Formula key

Scheduling Scheduling datadata

Available capacities of resources are the basis for scheduling process orders. They are also required for capacity requirements planning and shop floor control.

In order to calculate the execution time of an operation during process order scheduling, the available capacity of exactly one of several possible resource capacities is defined as the basis for scheduling.

To calculate costs, execution times, and capacity requirements of phases carried out at a resource, enter a formula key that refers to a suitable formula in the corresponding screens.

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8.7

SAP AG 1999

S

VAR = DV *PHQU

BAQU

Classification

Formulas

Cost centerassignment

Capacities

Personnel

Resourcenetwork

Resource Management Views

ClassA

Resources are used in the operations of the recipes and the process orders. With the resource, you can

Determine which processing units, persons, or other resources are to be used in the operations and phases of the recipe.Specify costs, capacity requirements, and dates for the operations and phases.

Persons are assigned to the resource to determine which employees are to work at this resource. Costs, execution times, and the capacity requirements of the resource can be calculated from standard

values using formulas. Activity types that are linked to a cost center are assigned to a resource via the cost center. You can

calculate in-house costs of an operation by assigning the resource to a cost center.

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8.8

SAP AG 2001

Cost Center / Activity Type / Resource

Resource Cost CenterFormula Activity types Charge rates

F1 A USD 10/hF2 B USD 20/h

.

. .

. .

Example :

Formula F1 Rate foractivity type A

x x Duration = Total time

(max. 6)

USD 10/h

Total timeTotal time

Operation qty

Standard values

Operation values

Resource constant

Base output

Base quantity Res. output

xx Charge rateCharge rate == COSTSCOSTS

The costs incurred due to the use of a resource in a phase must be calculated in production and order costing. For this, you must maintain costing data in the resource.

The link to cost accounting is created by assigning a cost center to a resource. For a specified validity period, you can assign a resource to one cost center only. The specific output of a resource is defined by assigning activity types specified in the cost centers to

the resource. Each activity type is valued with specific charge rates. The output (= total time) of a resource is calculated with the help of formulas. A formula is assigned to

each activity type. Finally, the costs are calculated using the output (= total time) of a resource and the corresponding

charge rates.

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8.9

SAP AG 1999

Creating a Resource

Customizing PP-PI

Manually

Copy

DefaultDefaultresourceresource

Resource 1 Resource 1a

Resource 1b

Resource 1c

You can create a resource for a resource category in PP-PI in the following ways:ManuallyBy using a predefined default value in CustomizingBy copying a resource that already exists

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8.10

SAP AG 1999

Resource Network

Charge Reaction Discharge

B1

B2

R1

R2

R3

E1

You can often use processing units in a specified sequence only. To represent this sequence in the system, you can create predecessor/successor relationships between resources in the form of resource networks.

During process planning, these networks are used to determine possible sequences in which a resource can be used to manufacture a batch.

If several similar resources are available in a network, it makes sense to decide on the resource to be used at the time of production and not before. To do this, you can define a resource that is to be used for planning purposes only. This resource represents several equivalent resources.

You can restrict the usage of resources defined for planning reasons only with the task list usage of the resource. In Customizing, you can set the Until release indicator for a task list usage. If a resource has been assigned to a process order whose usage is restricted in this way, the order cannot be released. Before releasing the order, you must replace the planning resource with a suitable individual resource. You can use the function of resource selection to do so.

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8.11

SAP AG 1999

Classification of Resources

Class: Mixing vessel

Class type: 019 "Work center class"

Object:

Reaction vesselReactor - 01

Characteristics

U/min 150 - 300Temp. 80 - 120°C

Object:

Oper. 10 "Stirring"(Mst. rec. "Colors")

Characteristics

U/min 170Temp. 85°C

. . .

Fits ?Fits ?

Resource selectionin the process order

You can add specific resource attributes to the resource data by classifying the resource with classes of class type 019 work center class. The resource attributes are stored as characteristics of a class and are assigned specific values in the resources.

Apart from resources, you can also classify operations of master recipes in classes of class type 019. This allows you to store specifications for a resource in an operation.

The characteristic values of classified operations represent the selection criteria for system-aided resource selection in the process order. This allows you to select a suitable resource just before production begins. The resource network must be taken into account for resource selection.

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8.12

SAP AG 1999

Avail. cap. maint.Avail. cap. maint.outside outside of the of the resourceresource

Avail. cap. maint.Avail. cap. maint.outsideoutside of the of the resourceresource

Available Capacity of a Resource

Resource

CapCat 010"Transport unit"

"Clean-out labor"CapCat 009Labor

CapCat 008CapCat 008Process. unitProcess. unit

"Clean"Clean--out labor" out labor" CapCat 009CapCat 009

"Labor""Labor"

Default values per Default values per capacity category and plantcapacity category and plant

orcopy

Pooled capacity

Customizing: Default capacity

ReferenceReference

ReferenceReference CapTRANSCapTRANSCapCat 010CapCat 010"Transport unit""Transport unit"

Avail. cap. maint.Avail. cap. maint.in thein the resourceresource

You can maintain and assign the capacity of a resource while processing the resource, provided the capacity data can be maintained for the resource category.

The capacity overview is the starting point for capacity maintenance from the resource. Different available capacities of a capacity category are identified using the version number. The version

of the available capacity that appears in the screen header as the active version is used during capacity requirements planning and scheduling.

When creating an available capacity, you can copy or reference capacities of different origins.

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8.13

SAP AG 1999

Maintaining Avail. Capacity Using Shift Sequences

Day 7Day 1 Day 2Shift definitionShift definition

. . .

. . .

Resources /Work centers

Shift sequence

Shift 1Shift 1Shift 1

Work startWork start

Work finishWork finish

BreaksBreaks

Shift 2Shift 2Shift 2

Shift 3Shift 3

You can use shift sequences to reduce the time and effort needed to maintain an available capacity. In a shift definition, you define the work start and finish times as well as duration of breaks, which are

valid for several resources. In a shift sequence, you maintain the sequence of certain shift definitions for several resources. You define shift sequences in Customizing.

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8.14

SAP AG 1999

Assignments to the Personnel System (HR)

Resource

ResourceMaster data

Line operator

Process order

Operation:Reaction

Resources:VesselVolume 10 m3Line operator2 years experience

Shift schedule

Capacities

Human resources

Resource network

2 yr 1 yr

You can only maintain assignments of personnel, qualifications, and position when the HR system is being used.

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8.15

SAP AG 1999

Reporting Functions for Resources

ResourcesResources

Which cost centersare assigned to them?

Which resources exist in a plant? Which capacities

are assigned?

Which hierarchy doesthe resource

belong to?

Which recipes use the resource?

Different reporting functions are available for the resources of your company. They provide information on, for example:

Which resources are available?Which cost centers are they assigned to?Which capacities have been defined for the resources, or which resources use a capacity?To which resource hierarchies have the resources been assigned?Which recipes use the resources?

In addition, you can use the Logistics Information System to carry out resource evaluations.

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8.16

SAP AG 1999

Copy and reference available capacities

Prepare for a system-aided resource selection by creating a resource network and using resource classification

Create a resource based on a default resource and by copying another resource

You are now able to:

Resources: Functions: Unit Summary

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8.17Exercises

Unit: Resources - Functions


Create a default resource

Create, copy, and classify resources

Create resource networks, maintain available capacities, and assign cost centers

The resources required to produce detergent in your plant must be maintained in the system. Resource selection is to take place just before production starts. You will therefore classify the resources and include them in a resource network.

After entering the data in the system, you will use various reports for the resources.

1-1 Creating a Resource

Create some resources using the Customizing settings you made in the previous unit.

1-1-1 Defining a default resource

Define a default resource for resource category RE## in plant 1100.

Tools -> Accelerated SAP -> Customizing ->Project Management -> SAP Reference IMG -> Production Planning for Process Industries -> Master Data -> Resource ->General Data Define Default Resource (Default Work Center)

Basic data tab

Description Resource

Person responsible R##

Usage O##

Standard value key SK##

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Specify that the system is not to check the standard values.

Default values tab

Control key K1##

Capacities tab

Capacity category M##

Other formula DUR##

Scheduling tab

Capacity category M##

Other formula DUR##

Costing tab

Cost center 4250

Activity type

Fixed time

1420

Activity type

Variable time

1420

Formula key

Fixed duration

FIX##

Formula key

Duration,qty-dep.

VAR##

Save your default resource.

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1-1-2 Creating a resource based on the default resource

Create resource T-DTM1## of the resource category RE## in plant 1100.

Resources menu / Resource -> Create

When you maintain the resource data, the system suggests values that were created in Customizing as default values.

Enter Charging vessel grp.## as the resource description on the Basic Data screen.

Copy the other default values suggested on the Basic Data screen without changing them.

Look at the other detail screens on:

– Default values

– Capacities

– Scheduling

– Costing

Click through the corresponding tabs.

While doing this, pay attention to the messages on the status bar.

The default values will not be copied automatically from the default resource until you run through the detail screens.

Save your resource.

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1-1-3 Creating resources with reference to existing resources

In plant 1100, create the resources in the following table that are of the category RE## by copying the source T-DTM1##.

Select all the views that are offered for selection on the Copy from screen and choose Copy.

You only have to maintain the resource description and perhaps the task list usage on the Basic Data screen. You can then save the resource without going through further detail screens. All of the data from the screens you selected are copied from the source.

Create the following resources:

Resource Description Task list usage

T-DTR1## Reaction vessel 1 grp.## O##

T-DTR2## Reaction vessel 2 grp.## O##

T-DTR3## Reaction vessel 3 grp ## O##

T-DTA1## Cooling tank grp ## O##

T-DTG1## Group reaction vessel grp ## C##

In which way is resource T-DTG1## restricted by task list usage C## ?

_____________________________________________

_____________________________________________

1-2 Capacities

1-2-1 Displaying the capacity data of a resource

Display the capacity data of your cooling tank T-DTA1##.

Which capacity category is assigned to it? Why?

_____________________________

_____________________________

Display the capacity header data of the capacity category assigned.

Choose Capacity Header Data.

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Where was the header data of this resource capacity originally created?

_____________________________

_____________________________

1-2-2 Creating a pooled capacity with available capacity intervals

Create a pooled capacity POOL-## (personnel pool group##) of the capacity category P## in plant 1100.

Resources menu / Capacity -> Create

The data that is maintained as the default capacity for each plant and capacity category in Customizing is automatically copied.

Set the Pooled capacity indicator.

Set the Can be used by several operations indicator.

The standard available capacity has an operation time of 24 hours. An average of 10 single capacities is available in the standard available capacity, and the rate of capacity utilization is 100%. Maintain the standard available capacity accordingly.

Enter the detailed information for the available capacity of your pooled capacity. Define an available capacity interval for the active version 1 “Normal available capacity” according to the following information.

Choose Interval avail. cap.

Choose Insert.

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Make the following entries on the Add Interval of Available Capacity screen:

Valid from: “Today”

Valid to: “End of this year”

Length of cycle: 1

Number of shifts: 3

Workdays: 1 (overrides factory calendar)

Specify the following shifts on the Create Capacity: Shifts screen:

Shf Start Finish Breaks No.

1 00:00:00 08:00:00 01:00:00 8

2 08:00:00 16:00:00 01:00:00 12

3 16:00:00 24:00:00 01:00:00 10

After defining your shifts, choose F3 Back.

Check the available capacity intervals that are now valid on the Create Capacity: Interval of Available Capacity screen.

Save your pooled capacity.

1-2-3 Assigning a pooled capacity

Assign your pooled capacity POOL-## of the capacity category P## to your cooling tank T-DTA1##.

Resource -> Change

Capacities tab

Choose Create capacity.

Check whether the capacity data has been copied correctly to the resource.

Position your cursor on capacity category P20 and choose Capacity Header Data.

Save the resource.

1-2-4 Referencing a capacity

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Assign the capacity category 010 (Transport) to your cooling tank, T-DTA1##.

Resource -> Change

Capacities tab page


On the Header Data screen for this capacity category, reference the available capacity of the capacity TRANS-00 of the capacity category 010.


Choose Reference avail. cap.

After entering the capacity on the Reference Available Capacity screen, you reference the available capacity by choosing Continue. You cannot process the referenced data within the resource. You do have the option of changing the available capacity data by choosing Copy.

Save your resource.

Display the capacity

TRANS-00 and check the data again.

1-3 Formulas

1-3-1 Formulas in the resource

On which screens in a resource is a formula key used to reference the formulas that were defined in Customizing? Display, for example, the resource T-DTA1## again.

______________________

______________________

______________________

What is calculated with each of the formulas?

______________________

______________________

______________________

1-3-2 Displaying and testing the formula in a resource

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You can display the formulas that are assigned to the formula keys on the resource screens. You can also test the formulas.

Display the formulas defined on the Capacities, Scheduling and Costing screens for one of your resources and write down the formulas.

__________________________________

__________________________________

__________________________________

Extras -> Formula -> Display

For example, test the formula on the Scheduling screen

Extras -> Formula -> Tests

General operation values: (for example)

Operation qty: 1000 kg

Base quantity: 100 kg

Standard values: (for example)

Duration, fixed: 10 H

Duration, variable: 1 H

Choose Calculate.

Result: Total duration = 20 H

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1-3-3 Formula constants of a resource

Assign the formula constant RESPOW (Resource activity) to one of your resources.

Note: Resource constants can be used as parameters in the formula for costing, capacity requirements determination, and scheduling. This can be useful for resources, for example, that have activity-dependent output.

Resource -> Change /

(for example) Choose Scheduling /

Extras -> Formula ->Formula constants

Param. Values UN

RESPOW (for example) 10,000

W

Which origin must be specified for a formula parameter in Customizing so that it can be used as a resource constant?

____________________________

1-4 Resource selection requirements

1-4-1 Creating a resource network

Create a resource network NETZ-## in plant 1100 according to the following graphic.

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0.2.2T-DTR1##

0.2.5T-DTR2##

0.2.6T-DTR3##

0.2.4T-DTM1##

0.2.3T-DTA1##

Make the following entries on the Header Data screen:

Description Resource network group ##

Person responsible R##

Assign the resources of the network shown in the graphic above.

Choose Resource allocation.

Choose the following selection conditions:

Plant: 1100

Resource: T-DT*

Resource Category: RE##

On the Resource allocations screen, select the resources and go to graphical maintenance.

Choose Graphic.

Create the resource network shown above in the graphic. Use drag and drop to position the resources as shown. Choose Connect and draw the links between the resources. Click in the blank area and go back one screen.

Save your resource network.

1-4-2 Displaying the network relationship of a resource

Display the data of the network resource for the reaction vessel T-DTR2##.

Resource -> Display

Goto -> Network -> Relationships

Goto -> Relationship detail

Header

Graphic

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1-4-3 Classification of resources

Classify your reaction vessel in class REAC_## (Reaction vessel) of the class type 019 (Work center class).

Assign values to the characteristics assigned for the individual reaction vessels in the following way:

T-DTR1## T-DTR2## T-DTR3##

Surface G

(glass)

P

(polyethylene)

S

(stainless steel)

Rev. per min 20 - 80 20 - 40 20 - 60

Save your data.

Classification is carried out for the purpose of system-aided resource selection in the process order.

1-5 Reporting

Resources / Reporting -> < ... >

1-5-1 Resource list

Display all resources that R## is responsible for in plant 1100. Be sure to remove any resources that have defaulted onto the selection screen.

Reporting ->Resources list

Note: Double-click one of the resources listed to display the corresponding resource data.

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1-5-2 Cost center assignment

Display the cost center that is assigned to your resources.

Plant: 1100

Work center: T-DT*##

Reporting -> Cost center assignment

Note: Double-click the objects listed to display data for the resources, cost centers, and activity categories.

1-5-3 Resource capacities

Display the capacities that are assigned to your resources.

Reporting -> Resource capacity

Plant: 1100

Work center: T-DT*##

Note: Double-click the capacities listed to display the corresponding capacity data.

1-5-4 Where-used list

In which master recipe is, for example, the resource T-IC101 from plant 1100 used? Use overview variant: L00000000100.

Reporting -> Where-used list ->Resource

For which resources is the capacity POOL-## from plant 1100 used?

Reporting -> Where-used list ->Capacity

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8.18Solutions

Unit: Resources - Functions

1-1 Creating a Resource

1-1-1 Defining default resources

Maintain the data as described for the exercise.

1-1-2 Creating a resource based on the default resource


1-1-3 Creating resources with reference to an existing resource


In which way is resource T-DTG1## restricted by task list usage C##?

The "Until rel." indicator (usage only until release in order) is set. An operation with this resource in its process order cannot be released. By this time at the latest, the resource must be replaced by a resource that physically exists.

1-2 Capacities

1-2-1 Displaying the capacity data of a resource

Which capacity category is assigned to it? Why?

M##. This capacity category was defined in the default resource and was copied when the resource was created.

Display the capacity header data of the capacity category assigned.

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When was the header data of this resource capacity originally created?

When the default capacity was defined for M## ( in Unit “Resources: Customizing”).

1-2-2 Creating a pooled capacity with available capacity intervals

Resources menu: Capacity -> Create

Choose Interval avail. cap.

Choose Insert.

1-2-3 Assigning a pooled capacity

Resource -> Change

Capacities tab


Check whether the capacity data has been copied correctly to the resource.


1-2-4 Referencing a capacity

Display and check the capacity TRANS-00

again.

Resources menu/ Capacity ->Display

1-3 Formulas

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1-3-1 Formulas in the Resource

On which screens in a resource is a formula key used to reference formulas that were defined in Customizing?

Capacities

Scheduling

Costing

What is calculated with each of the formulas?

Capacity requirements are determined

Operation time is calculated

Costs based on fixed and variable duration

1-3-2 Displaying and testing the formula in a resource

Display the formulas defined on the Capacities, Scheduling and Cost centers screens for one of your resources and write down the formulas.

Extras -> Formula -> Display

DUR##: Duration, Fixed + Duration, Var. * Phase Quantity / Base Quantity

FIX##: Duration, Fixed

VAR##: Duration, Var. * Phase Quantity / Base Quantity

For example, test the formula on the Scheduling screen

Extras -> Formula -> Tests

Choose Calculate.

1-3-3 Formula constants of a resource

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Resource -> Change /

Choose (for example) Scheduling /

Extras -> Formula ->Formula constants

Which origin must be specified for a formula parameter in Customizing so that it can be used as a resource constant?

Use the F1 help in the "Param." field on the "Formula constants" screen to answer this question.

Origin 1 “Work center constant”

1-4 Resource selection requirements

1-4-1 Creating a resource network

Resources menu / Resource network -> Create

Choose Resource allocation.

Choose Graphic.

1-4-2 Displaying the network relationship of a resource

Resource -> Display

Goto Network -> Relationships

Relationship detail

Header

Graphic

1-4-3 Classification of resources

Resource Change.

On the Basic data tab, choose Classification.

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1-5 Reporting

Resources / Reporting -> < ... >

1-5-1 Resource list

Reporting -> Resource list

1-5-2 Cost center assignment

Reporting -> Cost center assignment

1-5-3 Resource capacities

Reporting -> Resource capacity

1-5-4 Where-used list

Reporting -> Where-used list ->Resource

Reporting -> Where-used list ->Capacity

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9

SAP AG 1999

Mass processing: overview and access to recipe and BOM maintenance

Recipe editing

Approval

Consistency check

Contents:

Production Version

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Create, change, check, display, and delete production versions

Access master recipes and BOMs through production versions to edit them

Perform consistency checks for production versions


Production Version: Unit Objectives

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PP-PI Overview


Materials


Batches



Introduction






11

2

3

4

5

6

7

8

1

10

12

13

14

15



9 Production Version

Overview Diagram 9

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The products in your company are manufactured in different ways and are therefore managed in several different production versions.

You are responsible for maintaining production versions in individual or mass processing.

Production Version: Business Scenario

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Production Version: Definition

A production version determines which alternative BOM is used together with which master recipe to produce a material or create a master plan for a material.

More than one production version for different validity period and lot-size ranges can be assigned to a material.

Production versions are used in discrete manufacturing, repetitive manufacturing, and process manufacturing.

Production versions are used in sales & operations planning (SOP), material requirements planning (MRP), process order creation, and product costing to select the most suitable task list or recipe and the corresponding material list.

A production version comprises the following data: Material number, version ID, lot-size range, and validity period of the production version, details about whether the production version is locked, the date of the last consistency check, the assignment of master recipes to the production version, the assignment of the alternative BOM to the production version, a check status that displays the result of the last consistency check, the production line if the product is manufactured in discrete manufacturing, the change number that was used when the production version was last changed, as well as further administrative data.

When you create process orders that require approval, the system uses the change number to check whether the production version has been approved.

You can also select a production version without a recipe or BOM. Note, however, that if you do so, material quantity calculation data is not copied.

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Selection criteria for worklist creation:

Selection criteria:

Plant

Material

MRP controller

Key date

Task list type / group

Production line

Selection criteria:

Plant

Material

MRP controller

Key date

Task list type / group

Production line

Extended selection:

Header data

Lot size

Validity

Tas Lists

BOMs

Repetitive manufacturing

Extended selection:

Header data

Lot size

Validity

Tas Lists

BOMs


Production Version: Mass Processing (I)

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Copy

Assign change number

Delete

Create

Change

Check consistency

Lock

Create

Change

Check consistency

Lock

Production Version: Mass Processing

Maintain Prod.Version: Detail Screen

Production Version: Mass Processing (II)

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Worklist:Production version Task list group Grp cntr Alt. BOM

Recipe Key date (for change status)

Master recipe Bill of material

0001

0003

T-DET100

T-DET100

1

1

1

2

0002 T-DET100 2 2

Detailed plng grp: T-DET100

Group counter: 2Alternative BOM 2

... ... ... ...

Recipe Editing

From mass processing of production versions, you can navigate to the corresponding master recipe and create, edit, or display the recipe or alternative BOM there. From the production version, you can thus access all production related master data.

If you have assigned a change number to a production version, this number is also valid for recipe and BOM editing from the production version. This enables you to use an approval procedure in the same way for all related objects.

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PlantMaterialProd.version

Production version

Task lists

Bill of material

Check statusCheck status

Check statusCheck status

Lock

From lot sizeValid from

1100T-FD1000001

1 000 01/20/2000

1Group counterTask list group

T-DET100

Alternative BOM 1 BOM usage 1

Change no.assign.

Valid toTo lot size

12/31/200220 000

Recipe group for... 03/05/199903/05/1999Date of

last check

Check


Consistency Check

You can check whether the data of a production version is consistent with the data of the master recipe and the data of the alternative BOM assigned to it. You can then be sure that a valid recipe or valid BOM actually exists within the whole validity period of the production version.

In order for a production version to be consistent, it must fulfill the following requirements:The lot-size range of the production version must be in the lot-size range of the assigned recipe as well as of the assigned alternative BOM. This applies to all change statuses of the recipe and alternative BOM that are in the validity period of the production version. The assigned recipe and alternative BOM must exist during the whole validity period of the production version. The deletion flag must not be set for them.

If one of these requirements is not met, an error or warning message is given in the inspection result.

After the check, you can update the date of the last check and check status of the production version. The recipe, task list, or BOM are then assigned one of the following statuses in the production version:

Last check ok

Last check with warning

Last check with error

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Recipe group TRecipe group T--DET100DET100 Material TMaterial T--FD100FD100

Prod.vers. 0001Prod.vers. 0001

MaterialMaterial--recipe assignmentrecipe assignment

Material Recipe

T-FD100 T-FD100 1 1

MRPMRP viewview

Prod.vers. 0001Prod.vers. 0001

Recipe: 1

Change rule:• With an engineering change order

Mai

nta

inM

ain

tain

Mai

nta

inM

ain

tain

Production versionProduction versionMass processingMass processing

Mai

nta

inM

ain

tain

Change number

Validity period

Approval

Unlike recipe editing with a change master record or engineering change order, you do not create a new change status for the production version. You only assign the change number to it in the worklist for production version processing by carrying out the corresponding function. The change number is used to document or approve changes. If required, you must adjust the validity period of the production version manually.

You cannot use a change number when you edit production versions in the material master record. In the standard system therefore you cannot edit production versions whose change rule requires an engineering change order in the material master record.

A production version is considered approved when the following requirements are met:

The master recipe assigned to the production version has a change rule that requires an engineering change order with or without a change type.

The production version has been assigned a change number that complies with this change rule.

The relevant engineering change order has been released. This means you can no longer use it for changes.

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You can create, change, check, and lock production versions in detail maintenance.

In addition, you can copy and delete production versions in mass processing and assign change numbers.

From the production version, you can access all production-related data (master recipe and material BOM).

The consistency check ensures that a master recipe and BOM exist during the whole validity period of a production version.

Production Version: Unit Summary

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9.12Exercises

Unit: Production Version


Create and process production versions

Perform consistency checks for production versions

You are responsible for mass maintenance of production versions in your plant. You will create several production versions for the new detergent T-FD1##, since you are planning to produce it on different lines with different ingredients. You will therefore create production versions for different lot-size ranges, master recipes, validity periods, and BOM versions.

1-1 Creating a production version Create production version 0001 for material T-FD1## in plant 1100 using the following specifications:

Description of production version

Detergent 1

Valid from Today

Valid to Maximum validity date

From lot size 1000

To lot size 20000

Alternative BOM 1

BOM usage Production

Detailed plng grp: T-DET1##

Group counter: 1

Task list type: Master recipe

1-1-1 Which warnings appear after detail maintenance for the production version?

______________________________________________________

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______________________________________________________

1-1-2 Use the application help to find out more about the symbol that appears in the processing status column. What does this symbol stand for?

______________________________________________________

1-2 Copying from production versionsCopy the production versions created and change the copies according to the following instructions:

1-2-1 Copy production version 0001 to production version 0002 and change the number of the alternative BOM from 1 to 2.

1-2-2 Copy production version 0002 to production version 0003 and change the valid from date from today to today + 2 months in detail maintenance. Also change the number of the alternative BOM from 2 to 3.

1-2-3 Copy production version 0001 to production version 0004 and change the lot-size range from 1000 - 20000 to 20000 - 30000. Also change the group counter from 1 to 2.

1-2-4 Copy production version 0004 to production version 0005 and change the number of the alternative BOM from 1 to 2.

Save the production versions.

1-3 Consistency check for production versions /processing statusPerform a consistency check for production version 0003 of material T-FD1##.

1-3-1 Which messages appear in the consistency log?

______________________________________________________

______________________________________________________

1-3-2 How do you recognize that a consistency check has been performed on this production version?_____________________________________________________

_____________________________________________________

_____________________________________________________

1-3-3 What is the processing status?

________________________________________________________________

____________________________________________


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1-3-4 What changes with regard to the processing status after you save?

______________________________________________________

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1-4 Production version in the material master

The production version that was created in the previous exercise is defined in the master data record of the material T-FD1##.

Display the production version for material T-FD1## in the material master.

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9.13Solutions

Unit: Production Version

1-1 Creating a production version

SAP Standard Menu Logistics Production -Process Master Data Production Versions

Enter plant 1100 and material T-FD1## as your selection criteria.

Choose Refresh or press enter.

Choose Create production version

The Detail Maintenance: Production Version screen appears.


1-1-1 The following warnings appear:

No task list exists

No BOM exists

1-1-2 Help Application help

The symbol means the following:

Newly created or copied production versions

Save your production version.

1-2 Copying from production versions

1-2-1 Copy production version 0001 to production version 0002.

Select production version 0001.

Choose Copy production version

Enter number 0002 in the Copy/ProdVersion field.

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Choose Enter.

On the Production Version: Mass Maintenance screen, enter alternative BOM 2 for production version 0002.

Confirm the No BOM exists warning by choosing Enter.

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Choose Copy production version

Enter number 0003 in the Copy/ProdVersion field and choose Enter.

Double-click the entry production version 0003. The Detail Maintenance: Production Version screen appears. Change the Valid from date and the alternative BOM as described in the exercise.

Choose Close detail screen.

Confirm the No task list exists, No BOM exists warnings by choosing Enter.


Copy production version 0001 as described in 1-2-1.

Change the lot-size range and the group counter as described in the exercise.

Confirm the warnings by choosing Enter.


Copy production version 0004 as described in 1-2-1.

Change the alternative BOM number as described in the exercise.

Confirm the warnings by choosing Enter.


1-3 Consistency check for production versions /processing status


Choose Consistency check

The consistency log for production version 0003 appears.

1-3-1 The consistency log contains the following error messages:

Task list does not exist

BOM does not exist

Choose Back.

1-3-2 The current date was entered in the check date column. Additionally, the check status "Last check with error" (red light) is set.

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1-3-3 The processing status shows that the production version data was changed.

Note: The production version is therefore locked for other users until you save.


1-3-4 The following results when you save:

The symbol in the Processing status column disappears.

Note: This unlocks the production version.

1-4 Production version in the material master

SAP standard menu Logistics Production -Process Master Data Material Master Material. Display Display current

Display the MRP 4 view in the material master for material T-FD1##.

Choose ProdVersion.

On the Production Version Overview screen, the production versions just created are listed.

Select a version and press Detail to call the Production Versions Details screen.

If you enter the material master in the change mode, you can also create, check, and delete production versions if the production versions are not for recipes to be approved.

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Contents:


Elements and structure of a master recipe

Functions of a master recipe

Recipe-plant assignment

Recipe header data

Operations and phases

Resource assignment

Relationships

Scheduling

Classification of operations and resources

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Define the elements and structure of a master recipe

Describe the functions of a master recipe

Make assignments between recipes and plants

Create operations and phases

Assign primary and secondary resources

Create relationships

Classify operations

Carry out scheduling for a master recipe


Master Recipes, Operations, and Phases:Unit Objectives

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PP-PI Overview


Materials


Batches



Introduction Production Version





11

2

3

4

5

6

7

8

1 9

12

13

14

15

16


10Master Recipes: Operationsand Phases

Overview Diagram 10


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Master Recipes, Operations, and Phases:Business Scenario

The elements and structure of a master recipe that already exists will be presented.

Your company is going to put a new product on the market.

The production process is to be described in a master recipe.

You are responsible for creating a master recipe with operations and phases based on the resources used.

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A recipe that describes the production of one or several materials in a production process.

Master recipe

EBF/ISA(S88)/NAMUREBF/ISA(S88)/NAMUR

Proc. planning Proc. control

Control information

Quality inspec. data

Steps in the prod. process

Resources

Materials

Master recipe

Elements of a Master Recipe

Process order Process order Control recipeControl recipe

A master recipe defines the following data required for the manufacturing of materials without relating to a particular order

ResourcesMaterial componentsData for in-process quality inspectionControl information for the process control level

Master recipes have a planning and a control view. The planning view comprises the planning of operations, materials, resources, and inspection characteristics. Therefore, links to the R/3 application components PP, MM, SD, WM, and QM have been realized. The control view contains information required for communicating with the process control level.

The master recipe is the basis for the creation of process orders. A process order describes an actual production process. It contains all information specified during process planning, such as production date and quantities to be produced.

A control recipe contains all the information necessary for the execution of a process order by a certain process control system or a process operator. Control recipes are generated from the process instructions in a process order and transferred to the corresponding destination in process control. Process instructions are defined in the master recipe on which the process order is based.

Three organizations have defined the data that must be included in the standard recipe maintenance of the PP-PI application component:

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The European Batch Forum (EBF)The Instrument Society of America (ISA; with standards S88)NAMUR (Norms working committee for measuring and control techniques in the chemical industry).

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Recipe headerRecipe header

OperationsOperations

PhasesPhases

Process instructionsProcess instructions

Proc. instr. characteristicsProc. instr. characteristics

Resource network

Material (product)Primary resource

Structure of a Master Recipe (I)

The recipe header contains data that is valid for the whole recipe. At the header level, a resource network and the material to be produced is assigned to the recipe.

Operations describe the different steps required during the production process. For a more detailed description of these steps, operations are subdivided into phases.

Exactly one primary resource at which an operation is to be carried out is assigned to the operation. This assignment of the primary resource is also valid for all phases that belong to the operation.

Process instructions are structures with which data is transferred from R/3 process planning to process control. Process instructions are assigned to the phases of a master recipe.

Process instruction characteristics are assigned to process instructions and define the content of the process instructions together with the corresponding characteristic values..

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PhasesPhases



Secondary resources

Materialcomponents

Inspection characteristics

Relationships

Resource network

Material (product)Primary resource

Structure of a Master Recipe (II)

If required, you can assign additional secondary resources to operations and phases. If materials are added, temporarily created, or withdrawn at certain places in the production process, you

assign them to the corresponding operations and phases as components of a material list. Inspection characteristics specify which in-process quality inspections are to be carried out. They can

be assigned to operations and phases.

Relationships define the sequence of phases as well as link the start and finish points of phases.

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Process orderProcess order

MRPMRP

Cost accountingCost accounting

Master recipe



PhasesPhases



Primary resource

Functions of a Master Recipe

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EquipmentEquipment--testingtestingrecipesrecipes

Setup recipeSetup recipe

CleanClean--out recipesout recipes

Changeover recipesChangeover recipes

Non-Manufacturing Recipes

Master recipes can also be created for purposes other than the manufacture of materials. Non-manufacturing master recipes are, for example:

Equipment-testing recipesClean-out recipesSetup or changeover recipes

Equipment-testing recipes contain process instructions that are used to carry out and document periodic functional testing of a plant line.

Clean-out recipes describe the activities as well as the time, resource, and material requirements that are necessary to clean out a vessel after a production run.

Changeover recipes describes the activities necessary to transfer a processing unit from an initial state to a subsequent state.

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ProfileProfile

Default values for recipe maintenance for:

Default values for quality inspection

The operation

The relationship

The process instruction

The relationship graphic

Changeability

Profile for the Recipe

When creating a master recipe, you must enter a profile defined in Customizing. To display or change the default values set in this profile, choose Extras in the master recipe menu.

You can change the values in the profile dialog box. However, these changes are only valid until you exit the recipe.

In the profile, you can enter default values for the operation, the relationship, the increment of process instructions and process instruction characteristics as well as for the relationship graphic and how it is displayed.

Moreover, you can branch to a dialog box displaying QM data and enter default values for quality inspection.

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Recipe group Detergent production

Recipe

12

34

1100

Description

Detergent productionClean-out

Detergent productionClean-out

Plant

11001100

31003100

Productionplants

3100

Recipe-Plant Assignment

Master recipes that belong to the same recipe group can be assigned to different plants. When creating a master recipe, you can enter the plant number in the recipe header.

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Plant 3100

Plant 1100

Material components

Material listMat. qty calc.

Operations / phases

Copy

MaterialMaterial


BOMBOM

RecipeRecipe

RecipeRecipeOperations / phases

Copying Recipes from Other Plants

You can create a master recipe by copying another master recipe, even if they are from different plants. The material in the recipe header of the recipe being copied as well as the factory calendar are copied to the new recipe.

The other recipe objects, such as primary resources, control recipe destinations, process instructions, etc. are copied to the new recipe if they already exist in the target plant (otherwise error messages appear).

The data on the recipe detail screen of the new recipe is checked. The data must be changed if the entry does not exist in the target plant or is not the same as the resource data in the target plant.

Caution! The master inspection characteristics are not checked in the target plant. The system also does not check whether the process instruction characteristics that were copied have been released in the target plant.

To use the material assignments that have been copied to the new recipe, you must first create a production version to use the alternative bills of material in the new recipe.

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Master recipe

Mass changes Recipe: Replacing resource

Replacing process instruction Material list: Replacing material

Recipe changes:Which objects were created, changed, ordeleted for a recipe?

Material lists Structure Changes Quantity

Recipe list:Whichtexts forrelationshipssecondary resourcesmaterial componentsproc. instructionsPI characteristicsinsp. characteristicsare used in a recipe?

Where-used list:Which recipe uses a Resource Process instruction Material Document Class?

Reporting

You can evaluate the data of your recipe in the following ways:Evaluations on recipe changes: Documentation of changes made to all objects belonging to a recipe over a certain period of time.Where-used list for resources, process instruction categories, materials, documents, and classes.Evaluations of material lists: Evaluations of the structure and changes carried out for a material listMass changes: Replacing of process instruction categories and resources in master recipes. Replacing of materials in material lists.

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Material-recipe assignment

UsagePlanner groupStatus

Resource network

Recipe group, recipe counter, plant

Recipe header dataRecipe header data

Charge quantity rangeChange rule

Long text

QM data

Administrative data

Recipe Header Data

Data that is valid for the whole recipe is maintained on the recipe header level. A recipe is identified by the recipe group and the recipe counter. Recipes are defined on the plant

level. They can be grouped into recipe groups based on criteria defined by the user. By assigning a resource network, the physical network of the resources is described for the line at

which the process is to take place. The usage describes the purpose for which the recipe can be used (for example, production,

construction, plant maintenance). The planner group specifies a group of people who are responsible for the maintenance of the recipe. The status gives information about the processing status of a recipe (for example, creation phase, released for order, released for costing) and controls which business operations are allowed or not allowed.

With the charge quantity range, you specify a value range that is allowed for the production quantity and for which the master recipe may be used as the reference for a process order in production.

The material to be produced using the recipe is assigned to the recipe at the header level. To give more information, you can create a long text for the recipe header. On the recipe header detail screen for QM data, you determine whether an in-process inspection is to

take place with or without inspection points. Administrative data gives information about the validity dates of the recipe, who has created or

changed the recipe, and whether a change was made using a change number.

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.

.

.

CtrKCtrK

CtrKCtrK

CtrKCtrK

Operation 20Operation 20 ReactionReaction

Phase 21 Charge

Phase 22 Heat

Phase 23 Discharge

Operation 10Operation 10 ChargingCharging

Phase 11 Charge

Phase 12 Mix

Phase 13 Discharge

CtrKCtrK

Operation 30Operation 30 CoolingCooling

Phase 31 Charge

Phase 32 Cool

Phase 33 DischargeControl key

Operations and Phases

Operations describe the different steps required during the production process. For a more detailed description of these steps, operations are subdivided into phases.

You must enter a control key for each operation and phase. The control key determines how an operation or phase is to be processed in functions such as process orders, costing, and capacity requirements planning.

Control keys are defined in Customizing. You can set a number of indicators specifying, for instance: Whether scheduling is to be carried out for the phase Whether capacity load records are to be written for the phase Whether the phase is costed Whether a goods receipt is to be posted automatically for the process order when a confirmation is

received Whether time tickets are to be printed for the operation or phase Whether inspection characteristics have to be maintained for the operation or phase

Note: Scheduling, determination of capacity requirements, and costing take place at phase level. The dates and capacity requirements for operations are derived from the corresponding phases.

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Operation 30 CoolingOperation 30 Cooling

Primary resourceCooling tank

Var. start

Var. finish

Time

Secondary resource Line operator

Phase 31Charge

Phase 32Cool and check quality

Phase 33Discharge

Secondary resource Transport truck

CtrKCtrK CtrKCtrK

Assignment of Primary and Secondary Resources

Exactly one primary resource is assigned to an operation. The primary resource is that part of a line or processing unit at which the operation is carried out. It is committed for the entire duration of the operation.

The primary resource is also assigned to all phases subordinate to the operation in the hierarchy. If required, you can assign additional secondary resources to operations and phases. This assignment

can be carried out with a flexible start and finish time, relative to the start or finish of the operation or phase.

You must assign a control key to each secondary resource. The same business transactions can be carried out for secondary resources as for operations and phases. Secondary resources can, for example, be included in scheduling, capacity requirements planning, and costing.

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Recipe operation/phase

ResourceResource

Standard valuesf.ex. duration

Default values

Units for standard values

Control key

Standard text key

Wage data

Activity types

Rule for maint.Mandatory3

Ref.ind.

Ref.ind.

Ref.ind.

Ref.ind.

Standard and Default Values from the Resource

When you assign a resource to an operation or phase, you also assign the standard and default values maintained in the resource.

A standard value is a planned value for the execution of an operation or phase such as the execution time or operation quantity. Standard values are used in costing, scheduling, and capacity requirements planning to calculate costs, execution times, and capacity requirements.

Possible standard values for an operation or phase are defined in the corresponding resource. You can use a rule for maintenance to specify whether a standard value for an operation or phase may be, should be, or has to be entered. In the resource, you can also maintain default values for the units of measure of the standard values.

In the resource, you can maintain default values for the operation or phase data "control key" and "standard text key", for wage data as well as for the activity types to be assigned. These default values are then either copied into the operation or phase, giving you the possibility to later change them, or they are referenced into the operation or phase, thus making further changes impossible. In the latter case, a reference indicator is set for the relevant default value in the resource.

The control key specifies how an operation or phase is processed from a business point of view. Using the standard text key, you can choose a standard text created previously for the description of an

operation or phase.

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The specific output of a resource is defined by assigning activity types to the resource. Each activity type is valued with a specific charge rate (for example, USD 100/h). This forms the basis for calculating the costs resulting from activities performed.

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SAP AG 1999

Phase 31Charge

Phase 32Cool

Phase 33Discharge

Time

Operation 10Operation 10 ChargingChargingChargeCharge vevesselssel

Operation 30Operation 30 CoolingCoolingCooling tankCooling tank

Operation 20Operation 20 ReactionReactionReaction vesselReaction vessel

Phase 13Discharge

Phase 12Mix

Phase 11Charge

Phase 21Charge

Phase 22Mix

Phase 23Discharge

Relationships

Relationships determine the time-based sequence of phases. Relationships link the start and finish points of phases. This enables you, for instance, to synchronize phases belonging to different operations.

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SAP AG 1999

Recipe group "Production"Recipe 1

Recipe group "Clean-out"Recipe 1

Relationships Between Master Recipes

Phases from different recipes can be linked using relationships.

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SAP AG 1999

Float beforeproduction

Duration

Float afterproduction

Relationships !

Time

PhS PhF

SSBS BFSF

Ph11Ph11 Ph12Ph12 Ph13Ph13 Ph31Ph31 Ph32Ph32 Ph33Ph33

Ph21Ph21 Ph22Ph22 Ph23Ph23

Dates: BS:BF:SS:SF:PhS:PhE:

Basic startBasic finishScheduled startScheduled finishPhase startPhase finish

Scheduling in the Master Recipe

Scheduling a master recipe enables a time-based simulation of the manufacturing process in the planning phase. During scheduling, the start and finish times of phases are determined. Scheduling takes place at phase level only. The operation dates are derived from the phase dates.

Starting from the basic start or basic finish dates, scheduling is done either as forward or backward scheduling. You can enter a planned lot size if the phase duration depends on the quantity to be processed.

To be able to schedule, you must maintain default values for phases as well as relationships between phases.

Depending on the scheduling type, the float before production is either added to the basic start date, or the float after production is subtracted from the basic finish date. In this way you can determine the start and finish dates of production (scheduled start date, scheduled finish date).

The float before production and float after production are time buffers enabling you to react to disturbances in the manufacturing process. You can assign them to the material in the MRP view of the material master record using the scheduling margin key.

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SAP AG 2001

ResourceResource

Formula key for scheduling

Capacity category as a basis for scheduling

Formula constants

General operation values

Standard values Control key

"Scheduling"

Phase 11Phase 11 Phase 12Phase 12 Phase 13Phase 13

Operation 10Operation 10

PhSPhS PhFPhF

PhS PhF PhS PhF

OSOS OFOF

Duration

FormulaFormula

PhasePhase

Phase Duration

To calculate the phase duration, you must specify a capacity category as a basis for scheduling and define a formula in the resource.

The phase duration is determined on the basis of the standard values and additional formula parameters. When calculating the phase dates, the available capacity is taken into account as the basis for scheduling. Scheduling takes place via the phases. The operation duration is derived from the phase dates. The scheduling result can either be displayed in a table or graphically in a Gantt chart. Due to the relationships, phase dates can have a certain time buffer. Therefore, the earliest and latest start

and finish dates are determined in scheduling.

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SAP AG 1999

Class type 019 "Work center class"Class type 019 "Work center class"Class "Reaction vessel"

Characteristics:

Resource selection in the process order

Requirements Requirements --OperationOperation

1200 RPM

85° C

Fits ?Fits ?

Stirring speedTemperature

Classification of Operations and Resources

Attributes Attributes --ResourceResource

80-120° C

1000-2000 RPM

Using classes of class type 019 work center type, you can classify resources as well as operations contained in master recipes.

You can thus use the characteristics of a class of class type 019 in two ways: first, you can store specific resource attributes and second, you can define requirements a resource must meet if it is to be used in an operation of a master recipe.

The characteristic values of classified operations represent the selection criteria for system-aided resource selection in the process order´.

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SAP AG 1999

WEI

Consistency logHeaderHeader

Oper.Oper.

PhasePhase

Proc. inst.Proc. inst.

PI char.PI char.

Res. netwk

Material

Comp.

Sec. res.

Insp. char.

Relationsh.

Primary res. !QM data ismissing

CheckCheck

Checking the Recipe / Consistency Log

If you want to check whether the data for your recipe is complete and consistent, call the Recipe check function.

After the recipe is checked, warnings, information, and errors are collected for the recipe check in a consistency log.

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SAP AG 1999

Describe the elements and structure of master recipes.

Assign recipes of the same group to different plants.

Copy master recipe between plants.

Assign primary resources.

Define relationships.

Carry out scheduling.

Prepare system-aided resource selection by classifying operartions.

Master Recipes, Operations, and Phases:Unit Summary

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10.25Exercises

Unit: Master Recipes

Topic: Operations and Phases


Describe the elements and structure of a master recipe

Create a master recipe

Classify operations

Perform scheduling

The elements and structure of a master recipe that already exists will first be presented.


The production process will be described in a master recipe.

You are responsible for creating a master recipe with operations and phases based on the resources used.

1-1 Elements and structure of a master recipe

Go to mass maintenance for production versions in plant 1100 for group T-ICE##. Familiarize yourself with the data in the master recipe for production version 0001 of material T-FI1##.

1-1-1 Operation overview

Familiarize yourself with the operations, phases, and resources assigned.

1-1-2 Relationships

Display the relationships defined between the phases in the graphic.

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1-1-3 Recipe header data

Display the recipe header data.

Which materials are assigned to the recipe as products?

________________________

________________________

________________________

1-1-4 Material list

Familiarize yourself with the material components that are assigned to the recipe.

Which materials are assigned?

In which quantities are the material components required?

To which operations or phases are the material components assigned?

Material Quantity Operation

(5 examples are sufficient)

1-1-5 Process instructions

Display the process instructions maintained for phase 1010.

Which process instruction is assigned?

________________________

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1-2 Reporting and changing master recipes

1-2-1 Recipe list

Create a print list for the master recipe T-ICE##.

Master recipe menu / Reporting Recipe -> Recipe list

Task list type: 2

Plant:

Recipe group: T-ICE##

Recipe: 1

Material components are to be displayed for all BOMs.

Program -> Execute

1-2-2 Familiarize yourself with the further reporting functions that are available for the master recipe.

Master recipe menu / Reporting -> < ... >

1-2-3 Familiarize yourself with the mass changes that are possible for master data.

Master recipe menu / Mass changes -> < ...

1-2-4 Familiarize yourself with the settings you can make in the master recipe environment.

Master recipe menu / Environment -> < ...

1-3 Creating a master recipe: header data and operations / phases

Go to mass maintenance for the production version for material T-FD1## in plant 1100.

Create a master recipe for production version 0001 based on the following information:

Key date: today

Profile: 0001

1-3-1 Data for recipe header

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1-3-1-1 The Create Master Recipe: Recipe appears. Enter the following data on the Recipe header tab:

Description of the recipe: Recipe for detergent production, grp ##

Plant: 1100

Status: 4 “Released general”

Use: 1 “Production“

Planner group: 001 “Planner group PI”

Resource network: NETZ-##

Charge quantity range: 1000 - 20000 l

1-3-1-2 Header text

Create a long text that describes the recipe.

Choose Header text.

Header text: Recipe for detergent production, grp ##,

exothermic reaction

1-3-1-3 Administrative data

Display the administrative data.

Administrative data tab

1-3-2 Operations and phases

1-3-2-1 Creating operations and phases and assigning primary resources

Create operations and phases for your recipe 1 of the recipe group T-DET1## based on the data in the following table. Assign the primary resource.

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Operations tab

Op Ph SOp CRD Resource Description

100 T-DTM1## CHARGING

110 x 100 DE Charge

120 x 100 DE Mix

130 x 100 DE Add water

140 x 100 DE Discharge

200 T-DTG1## REACTION

210 x 200 DE Charge

220 x 200 DE Add Butanol and NaOH


300 T-DTA1## COOLING

310 x 300 DE Charge

320 x 300 DE Cool


Save your master recipe.

1-3-2-2 Control key

Use the input help (F4) to display detailed information about the control key K1##.

Which indicators are set?

____________________

____________________

____________________

Based on the indicators that have been set, what happens to a phase marked with this control key in the process order?

______________________________________

______________________________________

______________________________________

Use field help (F1) to display information about the functions of the different indicators.

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1-3-2-3 Text

Create the following text for operation 200.

Choose Text.

Text: Reaction

Resource selection condition have been defined for the operation so that a suitable reaction vessel can be selected.


Display the administrative data for an operation or a phase.

1-3-2-5 Maintaining standard values

Maintain the standard values for the phases of your recipe using the information in the following table.

The quantity-dependent durations should each refer to a base quantity of 1000 L.

Phase Duration, fixed

Act. type

Duration, variable

Act. type

(1st oper. value)

(2nd oper. value)

110 10 min 1420

120 30 min 1420

130 10 min 1420

140 10 min 1420

210 10 min 1420

220 30 min 1420

230 10 min 1420

310 10 min 1420

320 5 h 1420

330 20 min 1420

1-3-3 Assigning a secondary resource

Add the secondary resource T-DTT1## (Transport vehicle) for phase 330.

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SRes Resource Plant Description

0001 T-DTT1## 1100 Discharge into transport unit

1-3-3-1 Text

Enter the following text for your secondary resource.

Text: Discharge into transport unit:

The transport vehicle must be connected

15 minutes before charging begins.

It cannot be detached until 10 minutes

after charging has ended.

1-3-3-2 Resource dates

Define the earliest and latest dates of your secondary resource based on the following information.

Offset to start: 15- min. (Be sure to put a negative sign after 15 to indicate 15 minutes before)

Offset to finish: 10 min.


Display the administrative data for your secondary resource.

Save your recipe.

1-3-4 Relationships

1-3-4-1 Graphic maintenance

Create the relationships between the phases of your recipe as shown in the following graphic.

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Suggestion: Put the phases in the appropriate positions before connecting them.

1-3-4-2 Phase maintenance on the Detail screen

Maintain the last relationship in the corresponding detail screen for phase 320.

320------330

Rel. type Phase Scs (successor)

Rcp. grp Rcp. grp.

NF

Normal sequence

330 X T-DET1## 1

Display the detail information for this relationship.

Choose Details for the relationships created.

Display the administrative data for this relationship.


1-3-4-3 Displaying information in graphic maintenance

Go back to the graphic display of the relationships.

Double-click a phase. Which detail screen appears?

____________________

Double-click a line connecting two phases. Which detail screen for the relationships appears?

____________________

Save your recipe.

1-4 Classifying operations

Classify the operation 200 with the class REAC_## (Reaction vessel).

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Assign the following values to the characteristics:

Surface coating P

Revolutions per min. 30


The classification of the operation defines the selection conditions for a system-aided resource selection in the process order.

1-5 Scheduling

Suggestion: Do the following exercise for different charge quantities.

1-5-1 Scheduling overview

Simulate order scheduling in your master recipe.

Choose Schedule recipe.

Display the result in the scheduling overview.

1-5-2 Gantt chart

Display the scheduling results in the Gantt chart.

Choose Gantt chart.

Select a suitable time unit.

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10.26Solutions


Topic: Operations and Phases

1-1 Elements and structure of a master recipe

Production – Process Master Data Production Versions

Plant: 1100

Planning type: 2

Group: T-ICE##

Select production version 0001 of material T-FI1##.

Choose Recipe.

On the Parameter for recipe maintenance screen, choose Display recipe.


1-1-2 Relationships

On the Operations tab, choose Operation graphic


Recipe header tab

Which materials are assigned to the recipe as products?

Choose Material assignments.

T-FI100

T-FI200

T-FI300

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1-1-4 Material list

Materials tab

Material Quantity Op

T-RI000 0.1 KG 1010

T-RI100 0.12 KG 1010

T-RI200 0.16 KG 1010

T-RI300 0.02 KG 1010

T-RI400 0.02 KG 1010


Operations tab

Select phase 1010.

Choose Proc. inst.

Which process instruction is assigned?

INSTR

1-2 Reporting and changing master recipes

1-2-1 to 1-2-4

Production – Process Master Data Master Recipes

<....> Reporting Recipe Recipe list

Production versions

Recipe Recipe changes

Change documents

Material list <....>

Where-used list

Mass changes

Environment

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1-3 Creating a master recipe: header data and operations / phases


Select production version 0001 of material T-FD1##.

Choose Recipe.

Parameter for recipe maintenance: edit recipe

1-3-1 Data for recipe header

1-3-1 to 1-3-1-3


1-3-2 Operations and phases

1-3-2-1 Creating operations and phases and assigning primary resources

Operations tab

1-3-2-2 Control key

Use the input help (F4) to display detailed information about the control key K1##.

In the operation overview, position the cursor on the control key.

F4 help.

In the control key overview, position the cursor on the control key and choose Detail info.

Which indicators are set?

Scheduling

Det. Cap. Reqmnts

Cost

Based on the indicators that have been set, what happens to a phase marked with this control key in the process order?

The phase is scheduled

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Capacity requirement records are generated

The phase is costed

1-3-2-3 Text

Choose Text.


Double-click the operation/phase number.


1-3-2-5 Maintaining standard values

On the Operations tab, double-click each phase number.

Standard values tab.

1-3-3 Assigning a secondary resource

On the Operations tab:Select phase 330.Choose Secondary resource.

1-3-3-1 Text

On the Secondary resource tab:Select the secondary resource.Choose Text

1-3-3-2 Schedule

Double-click the item number of the secondary resource.Standard values tab



1-3-4 Relationships

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1-3-4-1 Graphic maintenance

In the operation overview (Operations tab), choose Operation graphic.

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1-3-4-2 Phase maintenance on the Detail screen

In the operation overview:Double-click phase number 320.

Relationships tab.

1-3-4-3 Displaying information in graphic maintenance

Operations tab

Choose Operation graphic.

Double-click a phase. Which detail screen appears?

Standard values of the phase

Double-click a line connecting two phases. Which detail screen appears for the relationships?

Relationships General Data screen

1-4 Classifying operations

On the Operations tab:Select operation 200Choose Resource selection criteria Goto -> Res. sel. criteria.

1-5 Scheduling

1-5-1 Scheduling overview

In the operation overview, choose Schedule recipe.

1-5-2 Gantt chart

Choose Gantt chart.

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11

SAP AG 1999

Contents:


Bill of material

Material list

Classification of bill of material items

Material quantity calculation


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11.2

SAP AG 1999


Describe what the material list and the bill of material are used for

Create a material list for a master recipe

Classify bill of material components

Define and carry out a material quantity calculation in the recipe

Master Recipes, Materials: Unit Objectives

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SAP AG 1999

PP-PI Overview


Introduction

Materials




Production Version






66

22

33

11

44

55

77

88

99

1010

1212

1313

1414

1515


Batches

1111 Master Recipes: Materials

Overview Diagram 11

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SAP AG 1999


As the person responsible, you will add a material list and a material quantity calculation to the the master recipe that has been defined for the production of the new detergent.

Master Recipes, Materials: Business Scenario

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SAP AG 1999

Catalyst

Product A

Product B

Ingredients

Operation 10 "Charging"

Catalyst

Intra material

Waste

Chargevessel

Operation 20 "Reaction"

Reaction vessel

Typical Material Flow in the Process Industry

The graphic shows two examples of operations carried out at the primary resources charge vessel and reaction vessel and the typical material flow in process manufacturing.

The graphic shows:Ingredients entering the production processThe temporary appearance of an intermediate product between two processing units which continues to be processed without leaving the process. Such materials are assigned material type INTR Intra material.Waste produced during the manufacturing process.The use of a catalyst that enters the process at a certain point of time and leaves it again later.The manufacture of one or more products. If several planned materials are manufactured during one production run, they are called co-products.

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SAP AG 1999

Bill of material







Operation 10

Material list


Operation 20

Operation 30

Phase 31

11


11

Material-Recipe Assignment (I)

The material to be produced is assigned to the master recipe at header level.

The structure of the product, which is the material to be produced along with the corresponding material components without operation and phase assignments, is defined in PP BOM Management as the bill of material (BOM). A fixed and unique link between the master recipe and BOM is defined in a production version. The production version is an attribute of the material to be produced.

The BOM data is used, for example, in material requirements planning and product costing.

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Bill of material

A complete, fully structured list of the components that

make up a product or assembly. The list contains the object

number of each component together with the quantity and

unit of measure.

Bill of materialBill of material






Bill of Material - Definition

Bills of material (BOMs) contain important basic data used in many different organizational areas. BOM data is, for instance, important for:

Material requirements planningMaterial staging during productionProduct costing

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SAP AG 1999

Bill of material








Operation 10

Material list


Operation 20

Operation 30

Phase 31

11

22

22

22

22Material-recipeassignment

11

Material component-operation/phaseassignment

22

Material-Recipe Assignment (II)

The material list contains all materials that enter, are temporarily created, and leave the process along with their planned quantities as components. It also defines the assignment of these material components to operations or phases of the recipe according to where they appear in the process.

A specific material list component is assigned to exactly one operation or phase. You can assign several different material components to an operation or phase.

In material quantity calculation, you define formulas to calculate the material quantities to be used or obtained in a production process, taking into account the mixing ratios of the ingredients, yield ratios of the products and remaining materials as well as specific material attributes (for example, concentration).

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SAP AG 1999...

YY--300 "Yellow paint"300 "Yellow paint" Base quantity : 5000 lProduct(Co-product)

BOM header

BOM items

...

Item 10 300 -110 Water 837 l

C

Item 20 300 -120 Diaminobenzol 1163 kg

Item 30 INTRA_01 Intra material 2000- kg

Item 40 INTRA_01 Intra material 2000 kg

Item 50 CAT_01 Catalyst 50 kg

Item 60 CAT_01 Catalyst 40- kg

Item 170 PA-300 Paste 500- kg

Ingredients

Intra material

Catalyst

Co-product

Bill of Material - Example

The graphic shows the structure of a bill of material (BOM) for a material. The product is assigned to the BOM header. A base quantity is defined in the BOM header and the

quantities of the material components entered in the BOM items refer to this base quantity. BOM items are, for example:

Ingredients, intra materials, catalyts, co-products, waste Quantities of materials entering the production process are maintained with a positive number, quantities

of materials leaving the process with a number followed by a negative sign. Materials that both enter and leave the process are assigned two different BOM items with the corresponding signs.

If a BOM item is a co-product, the corresponding indicator must be set for this item. In addition to this, the co-product assigned to the BOM header as well as the co-products listed as BOM items must be marked as co-products in their material master records.

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BOM Item Categories

When creating a new BOM item, you must assign each component toan item category.

The item category controls how the individual BOM items are processed.

Stock itemStock item

NonNon--stock itemstock item

VariableVariable--size itemsize item

Text itemText item

Document itemDocument item

Intra materialIntra material

Item Categories:

When creating a new BOM item, you must assign each item to an item category. The item category defines the attributes and functions of an item and controls how the individual BOM items are processed.

A BOM item category specifically designed for the process industry is category M for intra materials. The item category determines, for example:

Whether you must enter a material numberWhether quantity-based inventory management is to be carried out for this itemWhich sign is to be entered for the item quantityWhether sub-items can be usedWhat the screen selection and the screen layout of the item detail screens look like

Note that you cannot change the item category once you have created an item. You can only correct a wrong item category assignment by deleting the item and creating it again.

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SAP AG 1999

Ph 11Ph 11

Ph 12

Ph 31

Ph 32

Ph 33Ph 33

Ph 21Ph 21

Ph 22Ph 22

Ph 13Ph 13

Ph 23Ph 23

300 -110 Water 837 l

300 -120 Diaminobenzol 1163 kg

INTRA_01 Intra material 2000- kg

INTRA_01 Intra material 2000 kg

CAT_01 Catalyst 50 kg

CAT_01 Catalyst 40- kg

PA-300 Paste 500- kg

...

...

C

Material List

In the material list, the material components of the BOM are assigned to phases and operations. The material list is made up of components representing the materials entering and leaving the

production process, as well as temporarily existing materials and their planned quantities. It also defines the assignment of these material components to operations or phases of the recipe according to their appearance in the process.

A specific material list component is assigned to exactly one operation or phase. You can assign several different material components to an operation or phase.

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SAP AG 1999

YY--300 "Yellow paint"300 "Yellow paint"

BOM item as classifiable object

Class"Pyridene"

CharacteristicsSolubilityColor purity


Batch determination in the process order

Class typeClass type "Batch""Batch"

023_02

300 -110 Water

300 -120 Diaminobenzol

300 - 130 Pyridene

Characteristic values

light yellow40 - 60 kg/m3Solubility:

Color purity:

...

Classification of BOM Components

BOM components can be classified with class type batch in the master recipe. You thus store specific attributes that the planned material components must possess in the form of characteristic values for individual BOM items.

BOM components are classified for the purpose of material quantity calculation and batch determination. The characteristic values can be used in the formulas of material quantity calculation. The characteristic values defined in the process order are used as selection criteria during batch

determination.

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Material Quantity Calculation I

Material quantity calculationMaterial quantity calculation

Calculation of the material quantities to be used or obtained in a production process, taking into account the mixing ratios of the ingredients, yield ratios of the products and remaining materials as well as specific material attributes.

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SAP AG 1999

Characteristics

Concentration:80%

IngredientsIngredients

YieldYield

RawRawmaterialmaterial

CatalystCatalyst SolventSolvent

Remainingmaterial

Catalyst Product

Characteristics

Viscosity:15.5 cP

Material Quantity Calculation II

In material quantity calculation, you define formulas to calculate the material quantities to be used or obtained in a production process, taking into account the mixing ratios of the ingredients, yield ratios of the products and remaining materials as well as specific material attributes (for example, concentration).

Formulas for material quantity calculation can consist of:All quantities of materials in the material listThe characteristics and their valuesQuantities assigned to operations or phases

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Material Quantity Calculation - Example

Bill of material

Fruit juiceFruit juice

Treated waterTreated water



Material list

Master recipe: fruit juice production

Product: fruit juice Production version: 0001

MIXING OPERATIONMIXING OPERATION

- Charge

- Discharge- Discharge

- Mix

Fruit premix

Lemon juice

Sugar

The food division of your company produces fruit juice. At the beginning of the mixing operation, the individual components fruit premix, lemon juice, treated water, and sugar are charged into the mixer.

The fruit premix and lemon juice are listed in the material BOM and material list in their proportion units Liter fruit and Liter acid.

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Batch 1:Batch 1: 100 LF (B11)

Batch 2:Batch 2: 150 LF (B12)

and so onand so on

Quantity: 6.875 liter acid (LS) (C1)

40 -80 % acid content (C3)

Quantity: 350 liter fruit (LF) (B1)

80 - 100 % fruit content (B2)

3 - 5 % acid content (B3)

Lemon juice (C)Lemon juice (C)

Material Quantity Calculation - Process (I)

Batch determination:fruit premix

Recalculate product quantity

Adjust product quantity?

Fruit juice (A)Fruit juice (A)

Quantity: 1000 liter (A1)

35 % fruit content (A2)

2 % acid content (A3)

Fruit premix (B)Fruit premix (B)

B1 = A1 * A2

A1 = (B1n) * A2

C1 = A1 * A3 - ((B1n / B2n) * B3n )

You want to use a fruit premix with varying fruit and acid content to produce a fruit juice whose fruit content is always 35 % and whose acid content is always 2%. The fruit quantity in the fruit premix is thus calculated as follows:

Fruit quantity of fruit premix = Quantity of fruit juice * 35 %

The fruit premix has limited shelf life, therefore you want to use complete batches, i.e. no batch splits. The actual fruit quantity in the fruit premix may not equal the planned fruit content, so the product quantity and all component quantities must be adjusted. You adjust the fruit content of the fruit juice by mixing water with it. The acid content, on the other hand, is adjusted by adding lemon juice. Different lemon juice batches also have different acid contents.

The product quantity in the order is determined by the available fruit quantity in the fruit premix. The system must calculate the fruit juice quantity as follows:

Fruit juice quantity = Fruit quantity of fruit premix / Fruit content of fruit juice

To obtain the intended acid content of the fruit juice, you must balance variations in the percent of acid content of the fruit premix by adjusting the lemon juice quantity. This adjustment is not in proportion to the product quantity:

Acid quantity of lemon juice = Acid quantity of fruit juice - Acid quantity of fruit premix

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Quantity: 545 L (D1)

Quantity: 10 kilograms (E1)

Treated water (D)Treated water (D)

Sugar (E)Sugar (E)

Batch 1: Batch 1: 5 LS (C11)

Batch 2:Batch 2: 1.9 LS (C12)

Material Quantity Calculation - Process (II)

Add to obtain product quantity:

D1 = A1 - (B1n / B2n) - (C1n / C3n)

Batch determination:lemon juice

E1 = A1 / 100

(to exactly 100 g)

After batch determination has been carried out for the lemon juice, the actual acid quantity in the lemon juice and the actual fruit quantity in the fruit premix are known. The batch-specific quantity proportions of fruit and acid can be used to calculate the physical quantities of the fruit premix and lemon juice.

Treated water is added to obtain the product quantity. The amount of water required depends on the product quantity and the physical quantities of the fruit premix and lemon juice:Quantity of water = Quantity of fruit juice - Quantity of fruit premix - Quantity of lemon juice. When adding water, the quantity added is always rounded up to full liters.

Sugar is added to improve the taste of the fruit juice. The sugar dissolves completely. The amount of sugar added is to be approximately 1% of the product quantity. It is to be added in 100 gram portions.

(C) SAP AG LO305 17

11.18

SAP AG 1999

Material Quantity Calculation Screen

001 002

Components/operations

003

[ 003 , 001 ]Column number

Line number

Key

Select formula Insert formula Calculate prod. qty

MT = Material textOP = Operation

001 MT T-FJ100

002 OP Charge

003 MT T-RJ100

004 MT T-RJ200

-

Quantity Fruit content Acid cont..

1000 L 35 %

80 %

2 %

1000 L

3 %350 LF

Formula definition

[001,001] * ([001,002] / 100)

003,001 003T-RJ100:gquantity

The numbers in brackets define a "cell" consisting of line and column numbers (see key) The detail functions of material quantity calculation are:

Select formulaThis function selects the cell on which you have positioned the cursor and enters it in the formula section of the screen. Insert in formulaThis function copies the coordinates of the line and column in the formula section, for example, [003,001]. Save formulaThis function saves formulas but does not transfer the values into the material list. Save formula and copy result This function saves all formulas and copies the values to the material list and bill of material. Formula overview This function contains the quantities and value fields plus the corresponding formulas. References used in the formulas are replaced by the value and the description of the field to which they refer. Calculate product qty The system calculates the product quantity and subsequently updates all component, operation, phase, and scrap quantities for which formulas have been defined.

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11.19

SAP AG 1999

Product Quantity Calculation

Materialquantities

Materialcharacteristics

ID Material UnTotal quantity Fruit content Acid content

1

4

5

6

7

...

Fruit juice

Fruit premix

Lemon juice

Water

Sugar

L

LF

LS

L

KG

35 %

80 %

2 %

3 %

40 %

1000 1000

350

6.875

545

10 Qty (1) = Qty (4) / Fruit contentQty (1) = Qty (4) / Fruit content (1) (1)

10001000 == CSUM (4)CSUM (4) //(fruit content(fruit content (1)(1) / 100)/ 100)

The material, phase, and operation quantities for a recipe can be linked to each other in formulas. Material characteristics can also be entered in the formulas.

The formulas are used to calculate the relevant quantities when creating a process order. If a material or characteristic quantity is changed, dependent quantities can be recalculated. The product quantity in the order is determined by the available fruit quantity in the fruit premix. The

system calculates the fruit juice quantity as follows: Quantity of fruit juice = Quantity of fruit premix / Fruit proportion of fruit juice.

To calculate the actual fruit quantity of the fruit premix, the system must add the fruit quantities of the batches selected in the order.

Adding batch quantities or characteristic values - CSUM This function adds the batch quantities or the values in the characteristic column you specified for all batches of a material item. As long as no batches have been assigned to the material item, the function returns the quantity of the material item or the characteristic value of the material item.

The formula for material quantity calculation looks as follows:CSUM(004) / ( [001,002] / 100 )

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11.20

SAP AG 1999

Component Quantity Calculation (I)

Materialquantities



1

4

5

6

7

...

Fruit juice

Fruit premix

Lemon juice

Water

Sugar

L

LF

LS

L

KG

35 %

80 %

2 %

3 %

40 %

1000

350350

6.875

545

10

Qty (4) = Qty (1) * Fruit contentQty (4) = Qty (1) * Fruit content (1) (1) 350350 == Qty (1)Qty (1) **(fruit content(fruit content (1)(1) / 100)/ 100)

The fruit quantity of the fruit premix can be calculated using a percentage calculation. The formula for material quantity calculation looks as follows:

[001,001] * ( [001,002] / 100 )

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11.21

SAP AG 1999

Calculation Using Active Ingredient Quantities of Batches

Materialquantities



1

4

5

6

7

...

Fruit juice

Fruit premix

Lemon juice

Water

Sugar

L

LF

LS

L

KG

USERUSER--EXITEXIT

35 %

80 %

2 %

3 %

40 %

1000

350

6.8756.875

545

10

Qty (5) = Qty (1) * Acid contentQty (5) = Qty (1) * Acid content (1) (1) -- Phys. qty (4) * Acid contentPhys. qty (4) * Acid content (4) (4) 6.8756.875 ==Qty (1) * (Acid con.Qty (1) * (Acid con. (1) / 100)(1) / 100) ---- ( (Qty (4) / Fruit content( (Qty (4) / Fruit content (4)) * Acid content(4)) * Acid content (4))(4))

To obtain the intended acid content of the fruit juice, you must balance variations in the percent of acid content of the fruit premix by adjusting the lemon juice quantity. This adjustment is not in proportion to the product quantity:Acid quantity of lemon juice = Acid quantity of fruit juice - Acid quantity of fruit premix

The acid quantity of the fruit juice is calculated by multiplying the product quantity with the acid content of the fruit juice.

The acid quantity in the fruit premix is calculated by multiplying its physical quantity with its acid content. The physical quantity is calculated by dividing the fruit quantity by the fruit content. The following calculation must therefore be carried out for each batch of the fruit premix:Fruit quantity of fruit premix / Fruit content of fruit premix * Acid content of fruit premix. Afterwards, the results for the acid quantities of the fruit premix are added.A user exit is required for this complex calculation.

An SAP enhancement (user exit) for material quantity calculation can be used to enhance standard functionality. The following are just some of the features offered by this SAP enhancement:

Enhancement of input data through the inclusion of additional fields and columnsCalculation of values that cannot be calculated in the standard system

The formula for material quantity calculation is: [001,001] * ([001,003] / 100) - CPSM (004;005)

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11.22

SAP AG 1999

Calculation Using Physical Batch Quantities

Materialquantities



1

4

5

6

7

...

Fruit juice

Fruit premix

Lemon juice

Water

Sugar

L

LF

LS

L

KG

1000

350

6.875

545545

10

35 %

80 %

2 %

3 %

40 %

Qty (6) = Qty (1) Qty (6) = Qty (1) -- Phys. Qty (4) Phys. Qty (4) -- Phys. Qty (5)Phys. Qty (5)

545 = Qty (1) 545 = Qty (1) -- CQSM (Qty (4) / Fruit contentCQSM (Qty (4) / Fruit content (4)) (4)) -- CQSM (Qty (5) / Acid contentCQSM (Qty (5) / Acid content (5)) (5))

Treated water is added to obtain the product quantity. The amount of water required depends on the product quantity and the physical quantities of the fruit premix and lemon juice:Quantity of water = Quantity of fruit juice - Quantity of fruit premix - Quantity of lemon juice. The quantity of water added is always rounded up to full liters:

Adding weighted batch quantities of characteristic values: Quotient sum - CQSM. For each batch of a material item, this function divides the batch quantities by the value in the characteristic column you specified or the value of the first characteristic column by that of the second column. It then adds the results. The system interprets the characteristic value as a percentage if its unit of measure contains a percent sign (%).

As long as no batches have been assigned to the material item, the function divides the quantity of the material item by the corresponding characteristic value or the first characteristic value of the material item by that of the second value.

You may need this function, for example, to calculate the total of the physical batch quantities from the active ingredient quantities of batches based on the active ingredient concentration.

The formula for material quantity calculation looks as follows:[001,001] - CQSM(004;002) - CQSM(005;003)

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11.23

SAP AG 1999

Component Quantity Calculation (II)

Materialquantities



1

4

5

6

7

...

Fruit juice

Fruit premix

Lemon juice

Water

Sugar

L

LF

LS

L

KG

1000

350

6.875

545

10 10

35 %

80 %

2 %

3 %

40 %

Qty (7) = Qty (1) / 100 (to exactly 100 grams)Qty (7) = Qty (1) / 100 (to exactly 100 grams)1010 == Qty (1)Qty (1) DIV 10DIV 10 / 10/ 10

Sugar is added to improve the taste of the fruit juice. The sugar dissolves completely. The amount of sugar added is to be approximately 1% of the product quantity. It is to be added in 100 kilogram portions.

The quantity of sugar can be determined using a percentage calculation. The result is always to be rounded to 100 kilograms. The following basic function is used:

DIV - Division using integers; not intended for negative numbers. Example: 1015 DIV 10 = 101 The formula for material quantity calculation is as follows:

[001,001] DIV 10 / 10It returns results with no more than one decimal place.

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11.24

SAP AG 1999

Master Recipes, Materials: Unit Summary

The material to be produced is assigned to the recipe at the recipe header level.

The material list shows the assignment of the BOM components to phases.

BOM components are classified so that a system-aided batch determination can later be carried out.

Using material quantity calculation, you can calculate the material quantities required or obtained in a production process by considering the mixing ratios of the ingredients and yield ratios of the products.

(C) SAP AG LO305 24

11.25Master Recipes, Materials: Exercises


Topic: Materials


Carry out material-recipe assignment

Create a material list

Check a production version

Classify bill of material components

Set up material quantity calculation


As the person responsible, you will add to a material list and prepare a BOM component for system-aided batch determination in the master recipe for the new detergent.

1-1 Material-recipe assignment

Your master recipe T-DET1## describes the production of the material T-FD1##.

Check the material assignment in the recipe header.

How was this material assignment determined?

____________________________________________________________

1-2 Creating a BOM and material list for the product assigned

Create the BOM and material list for the assigned material.

Go to the material overview (Materials tab) of your recipe.

(C) SAP AG LO305 25

1-2-1 Bill of material for material T-FD1##

The initial screen for BOM maintenance appears. After entering the data, you can assign the required material components in the BOM. Enter the following data:

Item Item cat. Component Quantity

0010 L T-RD1## 975 liters

0020 L T-RD2## 400 liters

0030 N T-RD3## 1225 liters

0040 L T-RD4## 1000 liters

0050 L T-RD5## 1400 liters

Enter 5000 L as a base quantity in the BOM header.

Choose Header.

1-2-2 Material list for material T-FD1##

Choose Back. The overview screen for the material list appears. Assign the material components to the phases of your recipe based on the following table.

Component Phase

T-RD1## 110

T-RD2## 110

T-RD3## 130

T-RD4## 220

T-RD5## 220

Save your recipe.

(C) SAP AG LO305 26

1-3 Checking the production version

Perform a consistency check for production version 0001 of material T-FD1##.

Which messages appear in the consistency log?

____________________________________________________________

____________________________________________________________

What is the new check status for the production version?

____________________________________________________________

1-4 Classifying BOM components

1-4-1 In your master recipe T-DET1## for material T-FD1##, classify the BOM component T-RD1##.

You must classify the BOM components so you can carry out system-aided batch determination in the process order.

To which class of class type 023 Batch is the BOM item assigned? Why?

__________________________________

__________________________________

Define the following values for the class characteristics as batch selection conditions:

Concentration 40 – 50 %

Density 1.3000 - 1.4000 g/ccm


(C) SAP AG LO305 27

1-5 Material quantity calculation

To carry out material quantity calculation, you will create a production version and a master recipe for fruit juice production in your company.

The corresponding material master records are already available in the system. The master record for the fruit juice mixing line still needs to be created.

1-5-1 Creating a resource

Create resource master record T-JM1## of the resource category RE##. The description is "fruit mixing line".

Check the default values offered for the resource.

Fruit juice production only takes place in a two-shift plant.

Assign grouping 01 (for shift definitions and shift sequences) to your resource in the header data of the assigned capacity category. Choose Intervals and shifts and insert a new interval with shift sequence.

Choose the interval from today to today + 1 year and the shirt sequence M2.

Assign the fruit mixing line to the cost center for the production of food. Use the F4 help to find the cost center key.

Save the resource.

1-5-2 Checking the material master records

In addition to the materials considered in Unit 6 Batches: Settings for Active Ingredient Management, which are fruit juice T-FJ1##, fruit premix T-RJ1## and lemon juice T-RJ2##, treated water and sugar are also to be added to the master recipe for fruit juice production.

The material numbers to be used are:

Treated water = T-RI5##

Sugar = T-RJ3##

(C) SAP AG LO305 28

1-5-3 Creating production versions

Create a production version 0001 in plant 1100 for fruit juice T-FJ1##.

The lot size covers the range of 1000 to 20000 L. The production version is valid from today.

The master recipe for production version 0001 is maintained with group counter 1 for recipe group T-JUI1##. The corresponding alternative BOM number 1 is used in production.

1-5-4 Creating master recipes

Create master recipe 1 in recipe group T-JUI1## with the following data (profile: PI01) for the production version:

Description of the recipe: Fruit juice production, grp ##

Plant: 1100

Status: 4 “Released general”

Use: 1 “Production“

Planner group: 001 “Planner group PI”

Charge quantity range: 1000 - 20000 liters

1-5-4-1 Text for recipe header

Create a text for the header that describes the recipe.

Choose Header text.

Header text: Fruit juice production, grp ##

Base recipe for fruit juice production at the fruit juice mixing line.

(C) SAP AG LO305 29

1-5-4-2 Operations and phases

Create the following operations and phases for the recipe:

Op Ph SOp CRD Resource Description

100 T-JM1## Mix

110 x 100 SP Charge

120 x 100 SP Mix

130 x 100 SP Discharge

1-5-4-3 Material BOM

Create the following material BOM for the recipe:

Item: ICt Material component Quantity Unit of measure

10 L Fruit premix T-RJ1## 350 LF

20 L Lemon juice T-RJ2## 7.65 LS

30 L Treated water T-RI5## 570 L

40 L Sugar T-RJ3## 10 KG

Maintain the following data in the BOM header:

BOM text: Fruit juice

Base quantity: 1000 L

1-5-4-4 Material list

Assign all of the materials listed above to phase 110.

Save the master recipe.

(C) SAP AG LO305 30

1-5-5 Material quantity calculation

Maintain the required formulas in the material quantity calculation for master recipe T-JUI1##. Save the material quantity calculation without copying the results to the material list (and then to the BOM).

To produce fruit juice, we will begin with a fruit premix which has varying fruit and acid content. The fruit premix has a limited shelf life so complete batches must be used. Since the fruit content of the final product must be 35%, the quantity of fruit juice produced may have to be adjusted. Lemon juice is used to balance the variations of acid content in the fruit premix and to maintain a 2% acid content in the final product. Treated water is added (rounded up to full liters) to obtain the quantity of fruit juice . Finally, sugar is added (in 100 gram portions) to improve the taste. The sugar content is approximately 1% of the total product quantity.

The components fruit premix B and lemon juice C both consist of their active ingredients fruit and acid, as well as their carrier material water. The physical quantity will refer to the sum of the active ingredient quantity and the carrier material quantity.

To do the following exercise, refer to the slides Material Quantity Calculation - Process (I) and (II).

1-5-5-1 Product Quantity Calculation

The total quantity of fruit juice A1 is calculated by dividing the fruit quantity in the batches of fruit premix B1n by the fruit content of fruit juice A2 (which is 35%).

What is the calculation formula for the total quantity of the fruit juice (also the product quantity in this case)?

_____________________________________________

Familiarize yourself with the functions available in the application help for material quantity calculation.

What is the formula that is to be entered in the cell [001,001]?

_____________________________________________

What result appears in the Quantity column for product T-FJ1## after you enter the formula above?

_____________________________________________

(C) SAP AG LO305 31

How does this result change when you recalculate the product quantity for the fruit premix after batch determination in the process order?

_____________________________________________

_____________________________________________

(C) SAP AG LO305 32

1-5-5-2 Calculating the fruit quantity B1 in the fruit premix

The fruit premix has varying fruit and acid content. You need to use a quantity that will always produce a fruit juice with 35% fruit content and 2% acid content. The fruit premix B component is listed in the material list in its proportion unit LF (liter of fruit) which equals fruit quantity B1. It is calculated by multiplying the total quantity of fruit juice A1 by its fruit content in percent A2.

What is the calculation formula for the fruit quantity?

_____________________________________________

What formula must be entered in the cell [004,001]?

_____________________________________________

What result appears in the Quantity column for material T-RJ1## after you enter the formula above?

_____________________________________________

1-5-5-3 Calculating the acid quantity C1 in the lemon juice

In the product fruit juice, a certain acid quantity must be obtained (= 2 % of the total quantity of the fruit juice), which is a combination of the acid quantity in the fruit premix and the acid quantity C1 in the lemon juice.

What is the formula for calculating the acid quantity in the fruit juice?

Acid quantity in the fruit juice = _____________________

The acid quantity in the fruit juice is calculated from the total quantity of fruit juice A1 and the acid content of the fruit juice in percent A3.

To obtain the desired acid quantity in the fruit juice, the acid quantity contained in the lemon juice must be added to the acid quantity contained in the fruit premix batches.

The fruit premix is listed in the material list in its proportion unit LF and therefore also in its fruit quantity. Which calculation is required to be able to convert the fruit quantities B1n to the physical quantities of the fruit premix batches (unit of measure: liters)?

Physical quantity = ___________________________

The physical quantity must be multiplied by the acid content B3n to obtain the acid quantity of the fruit premix in the batches. For this reason, a USER-EXIT is used to enter the quotient of acid content and fruit content of the individual batches in the 5th column "Intermediate results".

(C) SAP AG LO305 33

Intermediate results = B3n / B2n

The acid quantity of the fruit premix is calculated from the product of the fruit quantity B1n and intermediate result in the 5th column.


_____________________________________________

What result appears in the Quantity column for material T-RJ2## after you enter the formula above?

_____________________________________________

1-5-5-4 Calculating the component quantity of treated water D1

After the fruit premix and lemon juice have been charged, water is added until the required product quantity is reached.

The total quantity of water is calculated by subtracting the two physical quantities of fruit premix and lemon juice from the total quantity of fruit juice.

What is the calculation formula for the total quantity of water?

_____________________________________________


_____________________________________________

What result appears in the Quantity column for material T-RI5## after you enter the formula above?

_____________________________________________

Change the formula so that the result is rounded down to the next whole liter.

What is the formula in cell [006,001]?

_____________________________________________

Use the same function to round the product quantity down to the next whole liter!

What is the formula in cell [001,001]?

_____________________________________________

1-5-5-5 Calculating the component quantity sugar E1

The sugar completely dissolves in the fruit juice. A sugar content of 1% of the product quantity ensures the best taste for the fruit juice.

(C) SAP AG LO305 34

100 grams of sugar should always be added to the fruit juice mixture per 10 liters of fruit juice. The sugar quantity is always weighed on the fruit juice mixing line to exactly 100 grams.

Which of the three formulas gives the correct result?

a) [001,001] DIV 100

b) [001,001] DIV 10 / 10

c) [001,001] / 10 DIV 10

_____________________________________________

Maintain the correct formula for calculating the sugar quantity.

Save the formula without copying the result to the BOM.

1-5-5-6 Formula test for different quantities of fruit premix

The fruit premix component is the starting point for all further material quantity calculations in this example. Use different active ingredient quantities of the fruit premix to check the function of the formula entered. Choose the formula for the component quantity of the fruit premix and overwrite it with the following values:

a) T-RJ1##: Quantity = 352 (LF)

(C) SAP AG LO305 35

Enter the new values of the other quantities:

Material Quantity

Fruit juice

Lemon juice

Treated water

Sugar

Recalculate the product quantity to adjust it. What are the new quantities?

Material Quantity

Fruit juice

Lemon juice

Treated water

Sugar

Which value has not changed, even though it is dependent on the product quantity?

_____________________________________________

Cancel material quantity calculation without saving.

b) T-RJ1##: Quantity = 370 (LF)

Enter the new values of the other quantities in the table below:

Material Quantity

Fruit juice

Lemon juice

Treated water

Sugar

Recalculate the product quantity to adjust it. What are the new quantities?

Material Quantity

(C) SAP AG LO305 36

Fruit juice

Lemon juice

Treated water

Sugar

Cancel material quantity calculation without saving.

(C) SAP AG LO305 37

11.26Solutions


Topic: Materials

1-1 Material-recipe assignment

Use the production version transaction to access your recipe T-DET1##.

In the recipe:

Recipe header tab


Material assignment resulted from the creation of production version 0001 for material T-FD1##.

1-2 Creating a BOM and material list for the product assigned

1-2-1 Bill of material for material T-FD1##

You are on the Material assignments tab.

Recipes tabChoose Materials.

On the Create Material BOM: Initial Screen, choose Enter.Enter the material components.

To enter the base quantity, choose Header,

1-2-2 Material list for material T-FD1##in the BOM header:F3 (Back)

Materials tab

Choose Create assignment.

1-3 Checking the production version

Task list exists (no warnings or errors)BOM exists (no warnings or errors)

(C) SAP AG LO305 38

Last check ok (green light)

(C) SAP AG LO305 39

1-4 Classification of BOM Components

1-4-1 In your master recipe T-DET1## for material T-FD1##, classify the BOM component T-RD1##.

Production versions

Select: Production version 0001

Choose Recipe.

Materials tab

Choose Bill of material.

Select: T-RD1##

Extras Batch classification.

To which class of class type 0023 Batch is the BOM item assigned? Why?

023_14 This class was used in the unit “Batches” to classify the raw material T-RD1##.

The BOM item inherits the classification from the material master.

1-5 Material quantity calculation

1-5-1 Create resource

SAP standard menu Logistics Production -Process Master Data Resources Resource Create.

Resource Category: RE##

Description: Fruit mixing line

When you maintain the resource data, the system suggests values that were created in Customizing as default values.

Copy the default values without changing them.

Capacities screen:


Enter grouping 01 for shift definitions and shift sequences.

Choose Intervals and shifts.

Choose Insert intervals.

Valid from: <today> Valid until: < today + 1 year >

(C) SAP AG LO305 40

Shift sequence: M2 < ENTER >

Costing screen:

Position the cursor on the Cost center field.

F4 – help: Cost center short text: *Food*

Cost center: 4271 Food Production

Save the resource.

1-5-2 Checking the material master records

Treated water = T-RI5##

Sugar = T-RJ3##

1-5-3 Creating production versions

SAP standard menu Logistics Production -Process Master Data Production Versions

Selection conditions:

Plant: 1100

Material: T-FJ1##

Choose Create production version.

Detail maintenance:

Material: T-FJ1##

Production version: 0001 fruit juice production

From lot size: 1000 To lot size: 20000

Valid from: <today>

Detailed planning:

Task list type: Master recipe

Task list group: T-JUI1## Group counter 1

Alternative BOM 1 BOM usage 1

Ignore warnings.

Close the detail screen.

1-5-4 Creating master recipes


Choose Recipe.

Final date: < today >

(C) SAP AG LO305 41

Profile: PI01


1-5-4-1 Text for recipe header

Recipe header tab


1-5-4-2 Operations and phases

Operations tab


1-5-4-3 Material BOM

Materials tab

Screen: Create Material BOM: Initial Screen Choose Enter.

Screen: Item Overview: General

Item: ICt Material component Quantity Unit of measure

10 L T-RJ1## 350 LF

20 L T-RJ2## 7.65 LS

30 L T-RI5## 570 L

40 L T-RJ3## 10 KG

Choose Header (or F6).

BOM text: Fruit juice

Base quantity: 1000

Choose Back.

1-5-4-4 Material list

Materials tab

Select all materials.

Choose Create assignment.

Assign to operation/phase: 110

Save the master recipe.

(C) SAP AG LO305 42

(C) SAP AG LO305 43

1-5-5 Material quantity calculation

1-5-5-1 Product quantity calculation formula:

A1 = (B1n) / A2

Formula definition in cell [001,001]:

CSUM(004) / ( [001,002] / 100 )

Result: 1000

This result changes immediately when the active ingredient quantity of the batch found for the process order is not equal to the active ingredient quantity planned. The product quantity adjusts itself to the active ingredient quantity found.

1-5-5-2 Fruit quantity calculation formula:

B1 = A1 * A2


[001,001] * ([001,002] / 100)

Result: 350

1-5-5-3 Acid quantity calculation formula:

Acid quantity in the fruit juice = A1 * A3

Physical quantity calculation formula

Physical quantity = (B1n / B2n)


[001,001] * ([001,003] / 100) – CPSM (004;005)

Result: 6,875

1-5-5-4 Water quantity calculation formula:

D1 = A1 - (B1n / B2n) - (C1n / C3n)


[001,001] - CQSM(004;002) - CQSM(005;003)

Result: 545,31


ROUND ([001,001] –CQSM(004;002) – CQSM(005;003))


ROUND (CSUM(004) / ([001,002] / 100))

(C) SAP AG LO305 44

1-5-5-5 Sugar quantity calculation formula:

Correct result: Formula b

1-5-5-6 Formula test

a) T-RJ1##: Quantity = 352 (LF)

Material Quantity

Fruit juice 1000

Lemon juice 6.8

Treated water 543

Sugar 10

Recalculated product quantity:

Material Quantity

Fruit juice 1006

Lemon juice 6.92

Treated water 549

Sugar 10

The sugar quantity has not changed. It is not increased by 100 grams until the product quantity is increased by 10 liters. Cancel without saving.

b) T-RJ1##: Quantity = 370 (LF)

Material Quantity

Fruit juice 1000

Lemon juice 6.125

Treated water 522

Sugar 10

(C) SAP AG LO305 45

Recalculated product quantity:

Material Quantity

Fruit juice 1057

Lemon juice 7.265

Treated water 576

Sugar 10.5

(C) SAP AG LO305 46

12

SAP AG 1999


Process management

Process instructions and control recipe destinations

Control recipe creation

PI sheet simulation

Contents:

(C) SAP AG LO305 1

12.2

SAP AG 1999

Master Recipes, Control View: Unit Objectives

Define the tasks of process management

Create and send control recipes

Define and simulate a PI sheet


(C) SAP AG LO305 2

12.3

SAP AG 1999

Overview Diagram 12

PP-PI Overview


Materials


Batches




Master Recipes: Operationsand Phases




11

2

3

4

5

6

7

8

1 9

10

13

14

15



12 Master Recipes: Control View

(C) SAP AG LO305 3

12.4

SAP AG 1999

Master Recipes, Control View: Business Scenario

The process manufacturing of the product will be controlled by process operators. As the person responsible, you will define a corresponding PI sheet in your master recipe.

(C) SAP AG LO305 4

12.5

SAP AG 1999

Process Management

ExecutionExecutionProcessProcessplanningplanning

ProcessProcessmanagementmanagement

ProcessProcesscontrolcontrol

R/3 or R/3 or external systemexternal system

Process order

Controlrecipe

Process messages

Furthermessage

dest.

ProcesProcescontrolcontrolsystemsystem

PI sheetPI sheet

Process management is the interface between PP-PI and the systems involved in process control. Due to its flexible structure, it can be linked to fully automated, partially automated, and manually operated lines. Process management comprises the following functions:

Receiving control recipes with process instructions from released process ordersTransferring control recipes to the corresponding process operators or process control systemsTranslating process instructions into natural language so that they can be displayed and maintained on the screen by the process operatorReceiving, checking, and transferring process messages with actual process dataManual entry of process messages

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Process management

Creating and Downloading Control Recipes

Text

PI sheetPI sheet

Process control system

Process control systemPI sheet

Control recipe destination:

Processorder

Manually operatedManually operated Automated

Phase 12Phase 11 Phase 13Phase 13 Phase 21Phase 21 Phase 22Phase 22 Phase 23Phase 23

Operation 10 Operation 20

DisDis--chargecharge

ReacReac--tiontion

ChargeCharge

DisDis--chargecharge

Charge Reac-tion

Using control recipe destinations, you specify the process operators or process control systems that are to carry out the process instructions of an order in the process order.

You assign control recipe destinations to the phases of the process order. This assignment is independent of the subdivision of operations into phases. This means that you can assign different destinations to phases of the same operation if this makes sense from the point of view of process control.

Process management creates one control recipe for each control recipe destination of a process order. A control recipe can only be created if all the phases involved are released. Once a control recipe has been created, you can no longer change the process instructions of the corresponding phases in the order.

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Process Instructions and Control Recipes

...

Oper. 100Oper. 100

Proc.instructionsPh 110Ph 110 CRD A1CRD A1


Proc.instructions

Ph 130Ph 130 CRD P1CRD P1

Oper. 300Oper. 300

Oper. 200Oper. 200

Proc.instructionsPh 210Ph 210 CRD P1CRD P1


Proc.instructions


Master recipe

...

Oper. 100Oper. 100



Proc.instructions


Oper. 300Oper. 300

Oper. 200Oper. 200



Proc.instructions


Process order

Dest. A1Dest. A1

Dest. P1Dest. P1

Dest. P2Dest. P2

Ctrl recipe 1

Ctrl recipe 2

Ctrl recipe 3

Process instructions are structures with which data or requests from R/3 process planning are copied to process control. Process instructions are assigned to the phases of a master recipe or process order.

Each phase must have a control recipe destination assigned to it. A control recipe destination indicates a process control system, a process operator, or a group of process operators to which the process instructions that have been created for the phase are to be transferred.

To execute an actual production process, a process order is created on the basis of a master recipe. Together with the control recipe destinations and process instructions, the operation and phase structure is copied from the master recipe.

Once a process order has been released for production, the process instructions to be sent to the same control recipe destination are grouped in a control recipe and transferred to process control. Exactly one control recipe is created for each control recipe destination.

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Ph 110

Ph 120

Ph 130

Ph 210

Ph 220

Ph 230

Ph 310

Ph 330

Op. 100Op. 100

Op. 200Op. 200

Op. 300Op. 300

Control recipe 2/Control recipe destination P1

Control recipe 3/Control recipe -destination P2

Ph110 Ph120 Ph130

Ph 210 Ph 220 Ph 230

Ph 310 Ph 320 Ph 330

Ctrl recipe 1 Ctrl recipe 2 Ctrl recipe 3

Control recipe 1/Control recipe destination A1

Planning view Control view

Example Recipe structure

Planning View and Control View

Ph 320

Op. 100Op. 100

Op. 200Op. 200

FILL MIX EMPTY

Op. 300Op. 300

FILL REACT EMPTY

FILL COOL EMPTY

Master recipes have a planning and a control view. The planning view comprises the planning of operations, materials, resources, and inspection characteristics.

In the planning view, phases are combined into operations. Phases are hierarchically subordinate to operations.

The control view contains information in the form of process instructions. This is required for communication with the process control level.

In the control view, phases are combined for a control recipe destination. Phases of a recipe that are combined for a control recipe destination do not need to belong to the same operation.

The graphic shows an example of an operation/phase structure, with two phases of different operations being processed in parallel. The parallel filling and emptying phases are monitored by the same process control system or process operator.

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Operation 100Operation 100

Proc. instr. 10Proc. instr. 10

PI char. 10

PI char. 20

Phase 110Phase 110PI sheetPI sheet

Instruction 1:Instruction 1:

Readtemperature

Temp:Temp:

Control recipe

PI Sheet

CRD 01Proc.oper.

Process order

Master recipe

The control recipe destination can either be an automatic process control system or a process operator in a production line that is manually operated (either totally or partially).

If a control recipe is sent to a process operator, the process instructions are prepared for display in natural language and interactive processing on the screen.

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Note:

PI SheetPI Sheet

Comment sheetComment sheetPI sheet 1000000449

Due to an error...Due to an error...

Received

Process order: 1234 Material: XYZ Test material

Operating group: W01

Phase 10 / Instruction 10Heat solvent.Start agitator.Add material ABC.

Note:Note:

Phase 10 / Instruction 20Check material quality.Record material quantity.Stop heating and slowdown agitator.

Temp.: ______ °CRot. speed:_____Quantity:_______kgSignature:_____

Record insp. resultsCall mat. qty calculationQuantity: ____ kgRot. speed: ______Signature: ____

Phase 10 / Instruction 30Start cooling and recordtime and temperatureevery hour.

Total quantity: ?___

Time10:0011:01

Temperature175.0168.3

Input values

Header

Controlinformation

Additionalinformation

Input values

Signature forproc. step

Formula result

Insp. resultsrecording

Function call

Comments

PI Sheet: Structure

The R/3 PI sheet contains the following elements:A header with general data such as order number, material number, and operating groupTexts containing control information and instructions for the process operatorAdditional information that can be called up using the corresponding pushbuttonComments maintained by the operators, which can be displayed using the corresponding pushbuttonInput fields (individually or in tables) for the actual process data to be reportedFields for formula results to be calculated by the systemThe Record inspection results pushbutton, which you can use to jump to the QM function for recording inspection resultsPushbuttons to call R/3 function modules in order to start a dialog (for example, order confirmation) or retrieve data from internal or external applications (such as R/3 Document Management)

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Phase

Process instruction view

Process instructions

PIassistant

Process instructioncharacteristics view

Alternativemaintenance

Master Recipe / Process OrderMaster Recipe / Process Order

Process Instruction Maintenance

You can use the PI assistant to maintain process instructions and process instruction categories. The PI assistant displays special selection views for each process instruction type. No knowledge of

process instruction characteristics or their use is required to work with the PI assistant. When you exit the PI assistant, the characteristic overviews of the process instructions are created.

You can use the PI assistant to:Define PI categories in CustomizingDefine process instructions in the master recipe or process order

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RecipeControl recipe dest. 10 Operating group 10Address GROUP 10Type 1 Control recipe transfer to R/3

PI sheetDigit. signature Required

InstCat ItemSequenceScope of gen.Filters

Description

OPTEXT 030100

At the start of an operation

Only one proc. instructionNo filter

SEQDEF 050105

At the start of a phase

For all predecessorsNo filter

Op. 10

Ph. 11 CRD A1

Displaying Generated Process Instructions

You can display information on the process instructions that are automatically generated for the recipe from the operation overview of the master recipe.

The system displays the following information for each control recipe destination assigned to the phases:The header data of the destination (for example, address, type, type of signature)The settings for the automatically generated process instructions (for example, process instruction category, item, scope of generation)

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Process controlsystem

PI sheet

Simulation

PPPP

PP-PIPP-PI

Production requirementsProduction requirements


Process managementProcess management



ProcessProcesscontrol levelcontrol level

Control recipe:Control recipe:proc.instructionsproc.instructions

PI Sheet Simulation in the Master Recipe

The effects process instructions and their characteristics have on the layout and structure of the PI sheet become visible only after the control recipe has been created. To check the PI sheet beforehand, you can simulate a PI sheet in the master recipe.

From within the master recipe, you can simulate a PI sheet or parts of a PI sheet in the following ways:For a control recipe destinationFor selected phasesFor selected process instructions

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Master Recipes, Control View: Unit Summary

Process instructions that have been assigned to phases are combined in control recipes.

One control recipe is created for each control recipe destination.

The control recipes are sent to the corresponding control recipe destinations.

A control recipe can be created to appear on the screen as a PI sheet for a process operator.

You can simulate a PI sheet from the master recipe.

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12.15Exercises


Topic: Control View

At the conclusion of these exercises, you will better understand:

Control recipe destinations


PI sheets

The process manufacturing of the product will be controlled by process operators.

As the person responsible, define a corresponding PI sheet in your master recipe.

1-1 Control recipe destinations and process instructions

Display the operation overview for recipe 1 of the recipe group COLORS.

1-1-1 Control recipe destination

Which control recipe destinations have been assigned to the phases of the recipe?

Input help F4 in the Destination field

CRD Description of control recipe destinations

____ __________________________________

____ __________________________________


Which process instruction categories are assigned to phase 1010?

To which process instruction types do they belong?

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In the operation overview:Choose Proc. inst for phase 1010

Input help F4 for Type field.

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ProcInstCat Type

__________ ___________________________

__________ ___________________________

__________ ___________________________

Which process instruction types have been defined in the R/3 System?

______________________________

______________________________

______________________________

______________________________

______________________________

______________________________

______________________________

Display the administrative data for a process instruction.

Choose Process instruction details and then the Admin. Data tab.

1-1-3 Process instruction characteristics

Which process instruction characteristics are assigned to the process instruction INSTR?

Choose Process instruction details.

______________________________

______________________________

The characteristics PPPI_INSTRUCTION and PPPI_NOTE are each assigned a long text. Display the long texts.

Display the administrative data for a process instruction characteristic.

Choose Details for process instruction characteristic and then the Administrative data tab.

1-1-4 Simulating a PI sheet

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Display the PI sheet for the phases with control recipe destination 01 in a simulation.

Choose Simulate PI sheet.

1-2 Defining a PI sheet in recipe T-DET1##

Create process instructions for your recipe T-DET1## using the information in the following table. Check and correct the texts and remove the process instruction characteristics you do not need.

The process instructions required for reporting material movement and order dates as well as other process instructions with information on operations, phases, and material components are all defined as automatically generated process instructions for the control recipe destination DE (See course LO060).

Note: In this exercise, you only have to define process instructions for instructions and notes for the line operator. Process instructions for in-process quality checks will be explained in a separate unit.

Phase 110:

PI ProcInstCat PI Characteristic

10 INSTR PPPI_INSTRUCTION (control instructions)

Long text (ZT-DET100-1): Fill the required quantity of raw materials T-RD1## (sulfuric acid) and T-RD2## (lauryl alcohol) into charging tank and confirm the filled quantity. Pay attention to the safety instructions.

PPPI_NOTE (note)

Long text (ZT-DET100-2): Caution! Corrosive material! Wear protective clothing, gloves, and protective mask.

Phase 120:


10 INSTR PPPI_INSTRUCTION (control instruction)

Long text (ZT-DET100-3):Turn on agitator. Mix ingredients for 10 min.

Phase 130:


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Long text (ZT-DET100-4):Add displayed quantity of water to mixture.

Phase 210:



Long text (ZT-DET100-5):Transfer material from charging tank to reaction tank. Start agitator.

Phase 220:



Long text (ZT-DET100-6): Carefully add the required raw materials T-RD4## (1 butanol) and T-RD5## (sodium hydroxide) to the reaction vessel. Confirm consumed quantities. Mix for 10 minutes. Pay attention to the safety instructions.

PPPI_NOTE

Long text (ZT-DET100-7): Caution! Wear protective clothing, gloves, and protective mask.

Phase 310:



Long text (ZT-DET100-8):Transfer the contents from the reaction vessel to the cooling vessel.

Phase 330:



Long text (ZT-DET100-9): Fill the product you just produced into the transport vehicle and confirm the quantity produced. Check if the cooling vessel is empty and close the valves.

PPPI_NOTE (note)

Long text (ZT-DET100-10): Wear protective clothing and gloves!

20 DE_PROD

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Simulate your PI sheet.

Save your recipe.

For more information, display the process instructions that are automatically generated in Customizing for the control recipe destination.

Goto Process management Control recipe dest.

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12.16Solutions


Topic: Control View

1-1 Control recipe destinations and process instructions

1-1-1 Control recipe destination

Logistics Production - Process Master Data Master Recipe Recipe and Material List Display

Operations tab.

Use the input help (F4) in the Destination field.

CRD Description of control recipe destinations

01 PI sheet for group 1

A1 PI sheet for group A1


In the operation overview, choose Proc. inst. for phase 1010.

Use the input help (F4) in the Type field.

ProcInstCat Type

INSTR Process parameter

READ2 Process data request

SIGN Process data request

Which process instruction types have been defined in the R/3 System?

Universal process instruction category

Process parameter

Process data request

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Process message subscription

Process data calculation formula

Inspection results request

Dynamic function call

Sequence definition

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Display the administrative data for a process instruction.

Choose Process instruction details and then the Admin. Data tab.

1-1-3 Process instruction characteristics

Which process instruction characteristics are assigned to the process instruction INSTR?

Choose Details for process instructions.

PPPI_INSTRUCTION

PPPI_NOTE

The characteristics PPPI_INSTRUCTION and PPPI_NOTE are each assigned a long text. Display the long texts.

Choose Values.

Display the administrative data for a process instruction characteristic.

Choose Details for process instruction characteristics.


1-1-4 Simulating a PI sheet

Display the PI sheet for control recipe destination 01.

Operation tab

Select phases.

Choose Simulate proc. inst.

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1-2 Defining a PI sheet in recipe T-DET1##

Operations tab

Select phases listed.

Choose Proc. inst.

Enter or select process instructions.

Choose Assistant or Details for process instructions.

Maintain control instructions or notes.

Choose Copy (only if you are maintaining in the assistant).

The control instructions and notes are defined in the system as standard texts. You can call up these texts in the long text editor by choosing:

Integrate Text Standard...

Enter text name ZT-DET100-*

Set Expand immediately indicator.

Simulate your PI sheet.Select all phases in the operation overview..

Choose Simulate proc. inst.

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SAP AG 1999

Material Master Maintenance

BOMs for the Manufacture of Co-Products

Contents:


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Aspects of Co-Product Manufacturing: Unit Objectives

Maintain the material master and BOMs for the manufacture of co-products

Create an apportionment structure for cost apportionment to co-products

Create a process order for a co-product

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PP-PI Overview


Materials


Batches








1111

22

33

44

55

66

77

88

1 99

1212

1010

1414

1515



13 Aspects of Co-Product Manufacturing

Overview Diagram 13

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Aspects of Co-Product Manufacturing:Business Scenario

Your company also produces fertilizer.

During the production process of the fertilizer, you want the co-product sulfuric acid to be produced.

As the person responsible, you will change the existing master recipe for fertilizer production regarding the manufacture of a co-product.

You must also make the corresponding changes to the material master of the co-products.

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Catalyst

Ingredients

Operation 10 "Charging"

Catalyst

Intra material

Waste

Chargevessel

Operation 20 "Reaction"

Reaction vessel

Co-product A

Co-product B

Typical Material Flow for the Manufacture of Co-Products

The graphic uses two examples of operations carried out at the primary resources charge vessel and reaction vessel to show a typical material flow in process manufacturing.

The graphic shows:Ingredients entering the production processThe temporary appearance of an intermediate product between two processing units which is processed further without leaving the process. Such materials are assigned material type INTR Intra material.Waste produced during the manufacturing processThe use of a catalyst that enters the process at a certain point of time and leaves it again laterThe manufacture of one or more products. If several planned materials are manufactured during one production run, they are called co-products.

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Co-product

Material YMaterial Y--300300

Cost-apportionment to co-productsApportionment structure Source struct.

Production version 1

Equivalence numbers

Material costs

Production costs

Y-300

P-300

10

1

Y-300

P-300

10

1

Production version 2...

...

00010002

PIPI

Y-300 and P-300Y-300 and Z-300

Material Master

The Co-product indicator must be set in the material master of a material that is to be manufactured as a co-product.

When manufacturing co-products, the entire costs incurred for the process order are collected at order header level and distributed to the individual co-products using equivalence numbers.

In the material master record, you define one or more apportionment structures. An apportionment structure specifies how the order costs are to be distributed to the co-products manufactured in a specific production process. You can maintain equivalence numbers for each apportionment structure and assign the apportionment structure to a production version.

When you create a process order, the system uses this data to automatically generate a settlement rule. This settlement rule is then used to distribute the total costs incurred to the co-products.

A source structure is used to distribute the equivalences in the apportionment structure according to cost element groups. How the costs are apportioned to the individual co-products can then differ according to the various cost element groups involved. You define source structures in Customizing.

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= Co-productC= Input material= Output material

+-

......

YY--300 "Yellow paint"300 "Yellow paint"

Co-product

Co-product

Leading productLeading product

C

300 - 100 Water +

300 - 120 Diaminobenzol +

P-300 Paste -

BOMS for the Manufacture of Co-Products

In PP-PI, the manufacture of co-products can be represented by assigning a co-product as a leading product to the BOM header. All other co-products appear as BOM items.

The following prerequisites must be met for the manufacture of co-products:The Co-product indicator must be set in the material master of the co-products.The Co-product indicator must also be set for BOM items that have co-products assigned to them.

The manufacture of co-products can also be represented using the material type PROC Process material. A process material is specifically used to represent the manufacture of co-products. A process material is not a physically existing material but rather it represents a manufacturing process. As a BOM header for a process material, all co-products of the manufacturing process are listed as BOM items with manufacture of co-product indicators. There is no quantity or value update for a process material. This transaction takes place at co-product level.

A process order can either be created for a co-product or for a process material.

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Material BOMs Master recipe

Quantity StructureQuantity Quantity StructureStructure

Prices for materials

Prices for activitiesPrices for activities

Overheads from costing sheet

Prices for processes

Value Structure

Value Value StructureStructure

Costing resultsCosting resultsCosting results

Itemization

M Material $M Material $E Activity $E Activity $G Overhead $X Process $

Costelements

$ $ $400 000 $610 000 $612 000 $660 000 $670 000 $

CostingCostingCosting

An

alys

isA

nal

ysis

An

alys

is

Pricing

Valuating

Profitability analysis

Controlling

PricingPricing

ValuatingValuating

Profitability analysisProfitability analysis

ControllingControlling

C

Material Costing: Objectives

Material costing uses data from Logistics, such as the material BOM and the master recipe, as the quantity structure to calculate costs for material consumption and the activities.

Material costing valuates this quantity structure with:

Prices for materials in the material master

Prices for activities in Cost Center Accounting

Prices for processes in Activity-Based Costing

Overhead on the direct costs for these materials and activities

Overhead for sales and administration costs

You can analyze the results in different ways

The analysis is used, for example, to estimate costs or for reporting

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Costing date from 04/01/2000

Costing date to 04/30/2000

Quantity structure date 04/01/2000

Valuation date 04/01/2000

Costing variantCosting variant

PlantPlant

MaterialMaterial

Lot sizeLot size

ItemizationItemizationCost Component Split

Cost Component Split LogLog

Mat Act. OH ProcessSystem messages

InformationWarning

Error

ExplanationExplanation

Executing a Material Cost Estimate

When you create a cost estimate with a quantity structure, you enter the costing variant, the material, the plant, and the costing version. If you do not enter a costing lot size, the default value from the material master record is used. The system determines and valuates the quantity structure automatically.

The dates are proposed from the costing variant and determine the following: The valuation of the quantity structure (valuation date) The validity period of the cost estimate (costing date from/to) The explosion of the quantity structure (explosion date)

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Aspects of Co-Product Manufacturing:Unit Summary

The manufacture of co-products is the production of several materials in one manufacturing run.

In the material master of the co-products to be produced, the Co-product indicator must be set.

One co-product is assigned to the BOM header as the leading product. All other co-products appear as BOM items.

A process order can be created in the BOM item for the leading product or for a co-product.

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13.11Exercises

Unit: Aspects of Co-Product Manufacturing

Topic: Master Data Maintenance


Set up a material master for co-product manufacturing

Create an apportionment structure

Extend a BOM to include co-product manufacturing

Your company also produces fertilizer.

During the production process of the fertilizer, you want the co-product sulfuric acid to be produced.

As the person responsible, you will change the existing master recipe for fertilizer production to reflect the manufacture of a co-product.

You must also make the corresponding changes to the material master of the co-products.

Scenario: The recipe T-RC1## describes the production of fertilizer. During the production process, the co-product T-FF3## (sulfuric acid) is to be produced along with the product.

1-1 Overview of master recipe T-RC1##

Familiarize yourself with the data in master recipe 1 of the recipe group T-RC1##.


Familiarize yourself with the operations, phases, and resources assigned.


Display the recipe header data.

Which material is assigned to the recipe as a product?

________________________

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1-1-3 Material list

Familiarize yourself with the material components that are assigned to the recipe.


________________________

________________________

________________________

1-2 Material master: Co- product indicator

Set the Co-product indicator for your materials T-FF1## and T-FF3## in the material master or make sure it is set.

Select view(s): MRP 2

Plant: 1100

For which material type was the co-product T-FF3## created?

Material type: _____________

1-3 Bill of material

Enter the material T-FF3## in the master recipe T-RC1## as a co-product in the bill of material of the “leading“ product T-FF1##.

Start recipe maintenance on the date of creation (previous exercise) in the material list.

Choose BOM.

Item ICt Component Quantity Un

0040 L T-FF3## 7- L

Set the Co-product indicator for the new BOM item T-FF3##.

Choose Item

Adjust the base quantity in the BOM header.

Choose Header.

In the material list, assign the co-product T-FF3## to phase 330.

Save your recipe.

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1-4 Material master: apportionment structure

For the fertilizer production process, create an apportionment structure for cost apportionment of the process order costs to the co-products T-FF1## and T-FF3##. Do this in the material master record of the leading product.


Plant: 1100

Choose Joint production.

Cost Apportionment to Co-Products: Apportionment Structures screen

Assign the source structure to PI so you can directly distribute the production costs to different cost elements.

Aufteilungsschema Schema

0001 T-FF1## and T-FF3## PI

On the Cost Apportionment to Co- Products: Equivalence Numbers screen, you can assign the groupings of cost categories already defined in the source structure to the Assignment field and distribute them to the co-products using the equivalence numbers.

Maintain the following equivalence numbers:

Choose Equivalence numbers.

Assignment Co-product EqNo

1 "Material costs" T-FF1## 10

1 "Material costs" T-FF3## 1

2 "Production costs" T-FF1## 5

2 "Production costs" T-FF3## 3

3 "Miscellaneous" T-FF1## 2

3 "Miscellaneous" T-FF3## 1

Save your material master record.

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1-5 Material master: Assigning an apportionment structure to a production version

In the material master record for the product T-FF1##, assign your apportionment structure 0001 to the corresponding production version.


Plant: 1100

Choose ProdVersion.

Choose Details.

1-6 Source structure in Customizing

In Customizing, display the source structure PI with which the production costs are directly distributed to the different cost elements.

Determine the source (cost element group) for each assignment in the PI source structure and write them down in the following table (enter controlling area 1000 if prompted):

Assignment Cost element group

Material costs

Production costs

Misc. costs

From the controlling application menu, display the cost element groups above and list three cost elements for each cost element group:

Cost element group Cost element

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1-7 Creating process orders for the co-products

1-7-1 Create a process order (order type PI01) for the leading product T-FF1## in production plant 1100.

Create Process Order: Header General Data screen

Total quantity: (for example) 1000 l

Basic dates: start (for example) today + 1 week

On the Operation Overview and the Material List screens, check whether the data from your master recipe has been copied correctly.

Also check whether the apportionment structure for the manufacture of co-products was copied correctly.

In the order header, choose Header -> Settlement rule

1-7-2 Create a process order (order type PI01) for the co-product T-FF3##.

Total quantity: (for example) 70 l


In the order header, the co-product T-FF3## is replaced by the leading BOM material T-FF1##.

The quantity to be produced for the leading BOM material is calculated from the target quantity for the co-product.

1-8 Material costing: Performing material costing with a quantity structure

You want to replan product costs for the fertilizer T-FF1## and the sulfuric acid T-FF3##. To do this, you will perform material costing with a quantity structure.

1-8-1 Write down the costing lot size for the fertilizer T-FF1## in the material master:

____________________________________________________________

1-8-2 Create a material costing estimate with quantity structure for the fertilizer T-FF1## in plant 1100. Choose the costing variant PPC1 Standard cost estimate (Mat) and confirm the dates suggested.

1-8-3 Go to the costing data and write down the status and the costing lot size:

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___________________________________________

___________________________________________

1-8-4 Write down the following quantity structure data:

Bill of material:

Alternative:

Task list group:

Group counter:

Process:

Production version:

Apportionment structure:

Use the F1 help to find out more about the Process field.

1-8-5 Which costing sheet was used for valuation?

____________________________________________________________

Display the cost in relation to the costing lot size.

Display the itemization for the cost of goods manufactured?

___________________________________________________________

An item category distinguishes costing items according to their cost source. What is the source of item category A?

____________________________________________________________

Save your material cost estimate.

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1-8-7 Create a material cost estimate with a quantity structure for sulfuric acid T-FF3## in plant 1100 with the costing variant PPC1 for costing lot size 7 L. Compare the data. What are the differences?

____________________________________________________________

____________________________________________________________

____________________________________________________________

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13.12Solutions

Unit: Aspects of Co-Product Manufacturing


1-1 Overview of master recipe T-RC1##

Master Data Production Versions

Plant: 1100

Group: T-RC1##

Select production version.

Choose Recipe.



Recipe header tab

Which material is assigned to the recipe as a product?


T-FF1##, Fertilizer, fluid, form A

1-1-3 Material list

Recipes tab

Choose Materials.


T-RF1##

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T-RF3##

T-RF2##

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1-2 Material master: Co- product indicator

Master Data Material Master Material -> Change -> Immediately


Plant: 1100

X Co-product

For which material type was the co-product T-FF3## created?

Choose Information on material.

Material type: Semi-finished product

1-3 Bill of material

Master DataProduction Versions

Plant: 1100

Group: T-RC1##

Choose Recipes.

Materials tab

Choose Bill of material.

Item ICt Component Quantity Un

0040 L T-FF3## 7- L

Set the Co-product indicator for the new BOM item T-FF3##.

Choose Item

x Co-product

Adjust the base quantity in the BOM header to 1000 liters.

Choose Header.

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1-4 Material master: Apportionment structure



Plant: 1100

Choose Joint production.

Cost Apportionment to Co-Products: Apportionment Structures screen

1-5 Material master: Assigning an apportionment structure to a production version



Plant: 1100

Choose ProdVersion.

Choose Details.

Apportionment structure 0001

1-6 R/3 Customizing IMG Controlling Product Cost – Controlling Product Cost Planning Selected Functions in Material Costing Costing in Joint Production Define Source Structure

Select PI source structure.

Double-click the Assignment folder.

Select each assignment and double-click the Source folder.

(Controlling area 1000)

Assignment Cost element group

Material cost CO – PC – MAT

Production cost CO – PC – PROD

Misc. costs CO – PC – MISC

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SAP standard menu Accounting Controlling Cost Element Accounting Master Data Cost Element Group Display

Cost element group: Cost element (example):

CO – PC – MAT 400000 Raw material

404000 Spare parts

405000 Packaging

CO – PC – PROD 620000 Machine costs

629600 Staging

625000 Setup

CO – PC – MISC 655300 OH Administration

655400 OH sales

416200 Electricity actual usage

1-7 Creating process orders for the co-products

1-7-1 Create a process order (order type PI01) for the leading product T-FF1##.

Logistics -> Production - Process -> Process Order / Process Order -> Create -> With material

Also check whether the apportionment structure for the manufacture of co-products was copied correctly.

In the order header, choose Header -> Settlement rule

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1-8 Material costing: Performing material costing with a quantity structure

1-8-1 Production -Process Master Data Material Master Material. Display Display current

Material: T-FF1##

Select view(s): Costing 1

Plant: 1100

Costing lot size: 1000

1-8-2 Production - Process Product Cost Planning Material Costing Costing with Quantity Structure Create

Material: T-FF1##

Plant: 1100

Costing variant: PPC1

Costing version: 1

Choose Enter.

Confirm the proposed dates by choosing Enter again.

1-8-3 Costing data tab

Status: Calculated without errors

Costing lot size: 1000 liters

1-8-4 Quantity Structure tab

Quantity structure data:

Bill of material: Unique number for each BOM

Alternative: 1

Task list group: T-RC1##

Group counter: 1

Process: T-FF100

Production version: 0001

Apportionment structure: 0001

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The Process field shows which process is used to cost a co-product.

1-8-5 Valuation tab

The costing sheet COGS, with which overhead costs are calculated, was used for valuation.

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1-8-6 Costing tab

Choose Itemization

The costing item with item category A has the co-product T-FF3## as its cost source.

Save.

1-8-7 Differences to first material cost estimate:

The costing structure is created from the sulfuric acid view. The fertilizer T-FF1## appears in the individual cost itemization with item category A.

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Inspection Lot

Specification of Batches Produced

Material Master

Master Recipe

Material Specification

Contents:

Aspects of Quality Inspection During Production

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Modify the material master for in-process quality inspection

Enter master inspection characterisics for the quality inspection

Prepare the master recipe for the in-process quality inspection


Aspects of Quality Inspection During Production:Unit Objectives

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PP-PI Overview


Introduction


Batches



Production Version




Materials


1111

22

33

11

55

66

77

88

99

1010

1212

1313

44

1515



1414Aspects of Quality InspectionDuring Production

Overview Diagram 14

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Aspects of Quality Inspection During Production:Business Scenario

Headache tablets are produced in the pharmaceutical subdivision of your company.

A master recipe for the production process is available.

As the person responsible, you will check the changes in the material master and master recipe that are specific to QM.

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50

40

30

20

10

Integration with Quality Management

Inspection specificationsConcentrationpH valueViscosity

R/3 QM insp. lot: insp. char.

QM-IDI

Ext. labor. information system(LIMS): analyt. specification

Inspection results recording20 %7.3100 cP

R/3 QM insp. lot: char. values

QM-IDI

LIMS: analytical results

Between the production plant and the laboratory or the quality assurance system, information on product quality and analysis values can be exchanged. This happens when the R/3 Quality Management System is used, with or without linking to external LIMS (laboratory information systems).

You define the specifications of a quality inspection in the inspection characteristics of an inspection lot in R/3 QM. During inspection results recording, the results of the quality inspection are assigned to the inspection characteristics of the inspection lot.

There is a direct link between PP-PI and R/3 Quality Management. The quality of materials produced can be checked in an in-process inspection taking place in parallel to the production process. In this case, the inspection lot is created for the corresponding process order. The inspection characteristics are created in the operations and phases of the master recipe the process order is based on and are then transferred to the inspection lot. Inspection results recording takes place when the process order is carried out. If the product is to be handled in batches, inspection results can be used for batch specification by automatically copying them to the class characteristics of the batch produced.

You can also check the product quality before a goods receipt after production. In this case, an inspection lot is created from an inspection plan maintained in R/3 QM.

R/3 QM can be linked to a LIMS using the QM-IDI interface. In this case, inspection specifications are transferred from R/3 QM to the LIMS, which in turn sends the inspection results back to R/3 QM.

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12

9

6

3

11 1

7 58 4

210

GoodsGoodsmovementmovement

Order(production)

SalesSalesorderorder

DeliveryDelivery

DeadlineDeadlinemonitoringmonitoring

ManuallyManually

Inspection lot

CreatedCreatedbyby

InspectionInspection

Inspection Lot

The functions of quality inspection of the R/3 System are fully integrated into the entire logistics process. They affect all business activities (such as product planning, production, procurement, and sales).

A quality inspection can only be carried out if an inspection lot is created. Inspection lots are fully integrated in the logistics chain, such as the neighboring R/3 tasks of goods receipt, goods issue, and process order. They document the entire inspection process, from inspection specifications to inspection results recording, and to the usage decision. They can be created automatically or manually from different sources of the corresponding application.

In-process inspection takes place parallel to the production process. The inspection lot is either created manually or automatically from within the process order when the order is released. The inspection characteristics are maintained for the operations or phases of the master recipe the process order is based on. They are then transferred to the inspection lot. The inspection results are recorded for the inspection characteristics of the inspection lot while the process order is carried out.

In other tasks, such as a goods receipt, the inspection lot is created on the basis of an inspection plan maintained in R/3 QM. Inspection plans are master data of R/3 QM.

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...

...

...

...

ManuallyAutom. at

order release

...

Inspection lotInspection lot

Insp. characteristic

Unplannedinsp. charact.

Inspection operation



Operation / phase

Material

Insp. characteristics

Insp. type:"In-process inspection of production order"

In-Process Inspection - Inspection Lot

In an in-process quality inspection, the inspection lot is created on the basis of the underlying master recipe. In the master recipe, you maintain inspection specifications in the form of inspection characteristics for the corresponding operations or phases.

You can either create the inspection lot manually or the system creates it automatically when you release the process order. For the system to be able to do so, you must activate the inspection type Inspection during production in the material master of the material to be produced. The inspection characteristics for the operations or phases of the master recipe are then transferred to the corresponding inspection operations of the inspection lot.

Later, you can also add unplanned inspection characteristics from within the process order.

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Master recipe

Operation / phase

Insp. characteristics

Prod. resource/tool (PRT)

Assignment of Production Resource / Tool to Inspection Characteristics

If tools or equipment are required for in-process quality inspection, you can assign production resource/tools to the phases and operations of a master recipe. You can then assign these production resource/tools to the inspection characteristics of the same phase or the same operation.

After the release of the process order, the assignment of the production resource/tool is transferred to the inspection lot. When inspection results are recorded, the production resource/tools of the phase or operation concerned is displayed.

Production resource/tools are mobile resources in production or plant maintenance. They are divided into the following categories:

MaterialsEquipmentDocumentsMiscellaneous production resource/tools

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Operation 10 Operation 20 Operation 30

Inspection char. C1

C2

C3 C4

C5

Insp. points

Inspection lot

Partial lot 1Partial lot 1

Partial lot 2Partial lot 2

C1 C1 C1

C2 C2 C2

C3 C3 C4 C4

C5 C5

Batch B2Batch B2

Batch B1Batch B1

Inspection Points, Partial Lots, and Batches

This graphic shows the general relationship between inspection points, partial lots, and batches. If you set the Inspection points indicator on the QM Data header detail screen of the master recipe, all

in-process inspection results recordings are carried out with relation to inspection points. Unlike inspection without inspection points, you can record inspection results for the inspection characteristics of the same inspection operation several times. The intervals between the inspection points can be time-related (that is, at certain points in time), quantity-related (that is, after a certain quantity has been produced), or freely defined.

Inspection results recording is performed for the inspection characteristics of the inspection lot with exactly one inspection lot being created for each process order. If partial quantities with different specifications are produced in a process order, you can assign inspection points to a corresponding partial lot to record inspection results. You can create several partial lots.

Partial lots describe a certain production quantity during production. This quantity is processed in several operations or phases. For each operation or phase, you can perform an inspection with inspection points for different inspection characteristics and assign the results to the partial lot. A new partial lot is created when the first inspection point of this partial lot is processed.

An example where partial lots are used is the manufacture of co-products, that is, the production of several materials in one process order. Each co-product can be represented by a partial lot.

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If the finished product is managed in batches, you can assign partial lots to individual batches. Selected inspection results can automatically be copied to the class characteristics of the batch for batch specification.

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Operation 10 Operation 20 Operation 30

C1: "Temperature"

C2: "Concentration"

C3: "pH value" C4: "Viscosity"

C5: "Color"

Insp. lot / Partial lot 1

QM master insp. characterist. Batch characteristicsLink

C2: Concentration: 20 %

C3: pH value: 6.5

C4: Viscosity: 100 cP

Concentration: 20 %

pH value: 6.5

Viscosity: 100 cPAutom. value transfer

ConcentrationConcentration

pH valuepH value

ViscosityViscosity

Batch B1Batch B1

Specification of Batches Produced

C1

C2

C3 C4

C5

In an in-process inspection, inspection characteristics for the operations and phases of the master recipe, which the process order or inspection lot are based on, contain inspection specifications. You can either create inspection characteristics in the master recipe or refer to already existing master inspection characteristics.

Master inspection characteristics are master data maintained in R/3 QM. They facilitate the maintenance of routine inspections and enable a linking to the class characteristics of batches. Due to this link, quality inspection results can automatically be copied from the inspection characteristics to the corresponding class characteristics of the batch produced.

If you choose inspection with inspection points, inspection points are assigned to a corresponding partial lot to record inspection results. You can assign several partial lots to an inspection lot. A partial lot describes a discrete production quantity that can be assigned to a batch. Once a usage decision for this inspection point has been made, the inspection results of an inspection point are transferred to the class characteristics of the batch linked to the master inspection characteristics.

If you want to carry out an inspection without inspection points, inspection results are recorded for the entire inspection lot. You can assign the production quantity to a batch. Once a usage decision for the entire inspection lot has been made, the inspection results are transferred to the class characteristics of the batch linked to the master inspection characteristics.

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Material

Classificationdata

Classification systemQuality Management

Batch class

Material SpecificationMaterial Specification

Master insp. charact. XMaster insp. charact. X

Master insp. charact. YMaster insp. charact. Y

General characteristic AGeneral characteristic A

General characteristic BGeneral characteristic B

AA

BB

XX

YY

Creating a Material Specification

To be able to transfer QM inspection results to the batch specification automatically, you must make the following settings:

You must define the general characteristics in which the inspection results are to be transferred as a numeric value. You should create the master inspection characteristics with reference to corresponding general characteristics. As a result, the value ranges of the general characteristic are transferred when you carry out a quality inspection with a material specification.You create a material specification for the material in QM. You can assign one master inspection characteristic to each general characteristic. With this connection, you clearly specify which master inspection characteristic transfers its result to which general characteristic. If you have created master inspection characteristics with reference to general characteristics of the material in the system, they are automatically transferred to the material specification.

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Insp. lot

023_08(colors)

General characteristics

Classification System

Master inspec. char.

Material TP-F3##

Batch_01

C001

C002

C003

Viscosity

Density

Wavelength

Class

9-114

9-112

9-111

Viscosity

Density

Wavelength

QM

Char. values:175 cP2.00 g/ccm 600 nm

In-Process Inspection - Example

The material to be produced TP-F3## belongs to class 023_08. The general characteristics C001, C002, C003 of the classification system are assigned to this class. Material specification allows the general characteristics to be assigned to the QM master inspection characteristics 9-111, 9-112, and 9-114. Parallel to the production process, the inspection requests are created as inspection characteristics in the operations or phases of the master recipe the inspection lot is based on, and transferred to the inspection lot. The inspection results are recorded for the inspection characteristics of the inspection lot while the process order is carried out. Since the finished product is to be handled in batches, the partial lot that has been produced can be assigned to a batch "batch_01". The inspection results are transferred to the classification characteristics of the batch produced during batch specification.

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Aspects of Quality Inspection During Production:Unit Summary

The quality of materials that have been produced can be checked in-process.

The prerequisite for a quality inspection is the creation of an inspection lot whose inspection characteristics are maintained.

The partial lots produced can be assigned to individual batches. In this case, inspection results can be transferred to the classification characteristics of the batch produced.

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14.14In-Process Quality Inspection: Exercises

Unit: Aspects of Quality Inspection During Production



Set up the material master for the quality inspection

Describe master inspection characteristics

Create a material specification

Prepare a master recipe for an in-process quality inspection

Make an inspection results recording for a phase in the PI sheet



As the person responsible, you will check the changes in the material master and master recipe that are specific to QM.

1-1 Material master: inspection type “In-process inspection of production order”

You must activate the inspection type In-process inspection of production order in the material master of your finished product. This will allow an in-process quality inspection to be carried out for process orders in the production of your material T-HT2## (Tablet Cetepharm-N). First check the settings for the material T-HT2##.

Select view(s): Quality Management

Plant: 1100

Choose Insp. setup

Insp. type: ___________________________________

Active indicator set: yes/no

1-2 Master inspection characteristics

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For tablet production, sieve size, water contents, and active ingredients contents are to be inspected during the production process. In QM master data maintenance, the corresponding master inspection characteristics have been defined.

Display the following master inspection characteristics for plant 1100. What are the descriptions for each characteristic?

Master inspec. char Description

N-100

N-200

N-300

Logistics -> Quality management -> Quality planning -> Basic data -> Inspection characteristic -> Display

The batch we will produce is to be specified according to the inspection results for the active ingredient potency. Which class characteristic is referred to by the master inspection characteristic N-300?

Master inspec. char Description Class char.

N-300

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1-3 Material specification

A material specification for your finished product must be created to allow the in-process inspection results of a batch to be transferred from the master inspection characteristic N-300 to the class characteristic N-006.

The link between master inspection characteristics and the class characteristics for a certain material is created during material specification.

Check the material specification defined for your product T-HT2##.

Material master menu -> Environment -> QM maint. functions -> Display matl spec.

1-4 Master recipe

A recipe has been maintained in the system for the production of the product T-HT2## (tablet Cetepharm-N).

Display recipe 2 of the recipe group T-TAB##.

1-4-1 Control key

In which phase is a control key selected that does not correspond with PI01 in the operation overview?

Phase number: ___________________

Control key: ___________________

Which indicator has been set for PI02 that has not been set for PI01?

____________________________________________

Choose F4 for control key PI02 . Choose Detail info for control key PI02.

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1-4-2 Inspection characteristics that have been defined

Which inspection characteristics are to be checked in phase 0021?


Choose Quant. data.

1-4-3 Process instruction QMJUMPPH

For phase 0021 "Mix" of the master recipe 2 of the group T-TAB##, only the process instruction "INSTR" (instructions with notes) is defined for the time being. Further process instructions will be automatically generated when creating a process order.

Data has been defined in Customizing for each control recipe destination “## + 70 ” (70 plus your group number).

On the Operations tab, choose Goto Process management Control recipe dest. to display the process instructions you want to generate.

At which position is a process instruction of the category QMJUMPPH generated in the control recipe? (This process instruction allows you to branch to the QM inspection results recording in a PI sheet.)

Position:

Description:

Which filter is set for the process instruction QMJUMPPH on the operation and phase level? Check this in Customizing for the control recipe destination.

______________________________________________

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1-5 Inspection results recording for phase 021

In the following exercise, you will perform an in-process quality inspection from the PI sheet (based on the master data displayed in the previous exercises 1-1 to 1-4).

1-5-1 Creating a process order for material T-HT2##

Create a process order of the process order type PI01 for the material T-HT2## in plant 1100.


Total quantity: 500 pieces

Basic dates: start: today + 1 week

Choose Enter and pay attention to the messages in the status bar. The master recipe T-TAB## (tablet production) is copied with the material list and the process order is scheduled.

In the operation overview and in the material list, check whether the data in master recipe T-TAB## has been copied correctly.

1-5-2 Releasing the process order and generating the control recipe

Release your order.

Choose Release.

Generate a control recipe for control recipe destination (## +70).

Choose Generating a control recipe.

Save your order and write down the process order number.

Process order number: _________________________

1-5-3 Sending the control recipe and maintaining the PI sheet

In the control recipe monitor, select the control recipe that corresponds to your process order and send it.

Process Management menu -> Control recipe -> Control recipe monitor

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Find and edit the PI sheet.

Process Management -> PI sheet -> Find

Confirm the start and finish of phase maintenance with your signature. Sign with your user name and confirm with your password.

1-5-4 Recording inspection results

Double-click the yellow Record inspection results field in phase 0021.

Enter a number to identify your inspection point and confirm by choosing Enter.

On the Record Results for Inspection Point: Characteristic Overview screen, enter results for the three inspection characteristics (sieve size, water content, potency of active ingredient) within the tolerance range (Result column).

After you enter the last inspection results, choose Enter to trigger automatic valuation. The recording is complete and can be saved.

Valuation and Partial Lot Allocation screen

Assign a partial lot to the inspection point.

Choose Create partial lot.

Assign a batch to the partial lot. Enter CHARGE01 as a description for the batch master record.

Choose Create batch.

The system takes you from the inspection results record to the PI sheet results.

Confirm the end of phase 0021 in the PI sheet with your signature and save the PI sheet.

1-5-5 Display batch with inspection results

Display the batch master record CHARGE01 for material T- HT2##.

Material master menu: Batch Display

Goto the classification data of the batch.

Classification tab

Check whether the value entered in the inspection results recording for the active ingredient content was transferred to the batch master record.

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14.15 Solutions

Unit: In-Process Quality Inspection


1-1 Material Master: Inspection type “In-process inspection of production order”

Material Master / Material -> Display -> Display current

Select view(s): Quality Management

Plant: 1100

Choose Inspection setting.

Insp. type: 03 = In-process insp. for production order

Active indicator set: yes

1-2 Master inspection characteristics

Display the following master inspection characteristics for plant 1100. What are the descriptions for each characteristic?


N-100 Sieve size

N-200 Water content

N-300 Potency of active ingredient

Logistics -> Quality management -> Quality planning -> Basic data Inspection characteristic -> Display

Master inspec. char Description Class char.

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N-300 Potency of active

ingredient

N-006

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1-3 Material specification

Check the material specification defined for your product T-HT2##.

Material master menu/ Environment -> QM maint. functions -> Display matl spec.

1-4 Master recipe

A recipe has been maintained in the system for the production of the product T-HT2## (tablet Cetepharm-N).

Display recipe 2 of the recipe group T-TAB##.

Production versions. Choose Recipe (for production version 0002).

1-4-1 Control key

In which phase is a control key selected that does not correspond with PI01 in the operation overview?

Phase number: 0021

Control key: PI02

Which indicator has been set for PI02 that has not been set for PI01?

Insp. char. required

Choose F4 for control key PI02. Choose Detail info for control key PI02.

1-4-2 Inspection characteristics that have been defined

Which inspection characteristics are to be checked in phase 0021?

Choose Insp. char for phase 0021.

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N-100 Sieve size

N-200 Water content

N-300 Potency of active ingredient

1-4-3 Process instruction QMJUMPPH

Operations tab

Select phase 0021.

Goto Process Management Control recipe dest.

At which position is a process instruction of the category QMJUMPPH generated in the control recipe?

Position: 06

Description: At the finish of a phase

Which filter is set for the process instruction QMJUMPPH at the operation and phase level?

(Suggestion: Open a new session)

Customizing: Process Management Control Recipe / PI Sheet

Define and Set Control Recipe Destination

Control recipe destination "## +70"

Process instructions to be generated

Choose Execute object for the process instruction category QMJUMPPH.

Selection criteria at operation/phase level:

The control key for the phase for which QMJUMPPH is to be generated must have the "Insp. characteristics expected" indicator set.

1-5 Inspection results recording for phase 021

1-5-1 Creating a process order for material T-HT2##

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Logistics -> Production - Process -> Process Order Process Order -> Create -> With material


Total quantity: 500 pieces

Basic dates: start today + 1 week

In the operation overview and in the material list, check whether the data in master recipe T-TAB## has been copied correctly.

Choose Operations.

Choose Materials.

1-5-2 Releasing the process order and generating the control recipe

Release your order.

Choose Release.

Generate a control recipe for control recipe destination "## + 70".

Choose Generating a control recipe.

1-5-3 Sending the control recipe and maintaining the PI sheet

In the control recipe monitor, select the control recipe that corresponds to your process order and send it.

Process Management menu Control recipe -> Control recipe monitor


Process Management PI Sheet Find

1-5-4 Record inspection results.

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1-5-5 Display batch with inspection results

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Change master record

Engineering change request

Changing master recipes

Recipe approval

Digital signature

Contents:

Engineering Change Management, Recipe Approval

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Engineering Change Management, Recipe Approval: Unit Objectives

Create change master records

Create engineering change requests / engineering change orders

Define the validity period of recipe objects

Carry out an approval procedure for a master recipe

Define digital signatures

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PP-PI Overview


Materials


Batches








1111

22

33

44

55

66

77

88

1 99

1212

1313

1414

1010



15Engineering Change Management,Recipe Approval

Overview Diagram 15

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Engineering Change Management, Recipe Approval: Business Scenario



To ensure regulatory compliance, you must follow an existing status profile for recipe approval to change the master recipe.

As the person responsible, specify the changeability of your master record accordingly.

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Eng. changemgmt

Material masters

Task lists- Master recipe

- Routing- Reference oper. set

- Inspection plan - Equipment task list- Gen. maint. task list

DocumentsClasses

CharacteristicsClassification

Configuration profileObject dependencies

BOMs- Material BOM

- Document structure

- Equipment BOM

- Functional location BOM

- Order BOM

Objects Linked to Engineering Change Management

Engineering change management is a central, integrated part of product data management (PDM) within the standard system.

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For different objects

At the same or different times

With cross-application and specialdocumentation

Monitoring and documentation of changes

Planning and realization at a specified time

Saving several change statuses of an object

Integration with the logistics process chain

Grouping of related changes

Why Use Engineering Change Management for Changes?

Engineering change management is a central logistics function that can be used to change various types of master data and document the changes.

A valid-from date for the change master record (or the engineering change request/engineering change order) is used to make changes valid on a predefined date. This aids long-term planning.

You can use engineering change management to store R/3 objects (for example, BOMs or routings) more than once. This means that the objects can be stored in all relevant change statuses.

The changes take effect automatically at the predefined time in all areas of the logistics process chain (for example, sales order, material requirements planning, and shop floor and production control).

You can use engineering change managment to group changes to different R/3 objects that are affected by one change. You can change all the objects at the same time, or you can define different change dates for individual objects. You can create general documentation for all changes made as well as special documentation for each specific object change.

You can use engineering change management to fulfill your legal obligations to document changes.

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Old

New

+

Old

New

Old

New

Change documents +

Without history(without change docu.)

Without history(with change docu.)

With history(with change docu.)

Change documents

Engineering Change Management: With and Without History

ECM

You can perform object changes (for example, BOM and routing changes) in the system either with or without history. The system generates change documents even for changes without history.

Changes without historyThese are changes that do not have to be documented because they take place during the development stage of the product, for example.The status of the object before the change is not saved. You can only find out about the status of the object before the change by using change documents.

Changes with historyThese are changes that must be documented because they take place during production, for example.Both the status before and after the change is saved. The system also generates change documents. These change documents differ for some objects from those generated for changes without history.Engineering change management in the SAP System allows for complete documentation of changes. Some of these changes may be needed for product liability purposes, for example.

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Advance planning / validity period of changes

Def. of object types (such as recipes, BOMs, etc.) that can be changed

Def. of objects (such as recipe "REC-101") that can bechanged

Def. of authorizations required for change master recordmaintenance

Complete documentation of changes

Changemaster record

- Change number

FunctionsFunctions

Change Master Record (Change Number)

Change master records (synonymous with change numbers) are used to plan changes in advance and combine related changes to different objects, such as master recipes, materials, and bills of material. They are created within engineering change management and can contain such information as:

The date from which the changes are to be validThe types of objects and, if required, object management records for the individual objects to be changed A special authorization that you need to work with the change master record

You can create, change, or display a master recipe with reference to a change master record. The valid-from date in the master record is then used as the key date. This implies:

When you create a recipe, the new recipe is valid from this date.When you display or change a recipe, the system selects the change status valid on this date.Unlike recipe maintenance without a change number, the system creates a new change status for all changed objects. This change status is valid from the valid-from date of the change number.

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Change number Valid-from date Authorization group Reason for change

Master recipes Material BOMs Documents

For example, master recipe "Colors"

Change headerChange header

Object typesObject types

Object mgmt recordsObject mgmt records

Structure of a Change Master Record

In the change header, a short description of the change, the valid-from date, and the status is maintained. You determine which objects can be changed with the change master record by selecting the object

types. One of the functions of the object management record is to enable you to document changes to a specific

object.

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1993

When was the change carried out?

Why was the change carried out?

State after the change?

Change on 12/01/93

State before the change?

?

Recipe "COLORS"

Change Change withwith historyhistory

Fromto05/01/9312/01/93

PI10

ProcInstCatXY

Recipe "COLORS"Fromto05/01/9312/01/93

PI10

ProcInstCatXX

Change Documentation

A change becomes effective on a precisely defined date. The changed object is stored twice: in its state before and after the change. The state of the object

before the change ends with the valid-to date. The state after the change begins with the valid-from date. Changes are documented in a change master record.

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Key date

Key dateKey date

ValidityValidityperiodperiod

Time

Validity ofoperation 1

Validity ofrecipe header

Validity ofrecipe header

Validity ofoperation 2

Engineering Change Mgmt - Validity Period of Recipe Objects

Every recipe object (such as, header, operation, material component) has a validity period. You can determine the start of this validity period using the key date you enter when creating or changing a recipe or recipe object.

When you create a recipe, the recipe becomes valid from the key date.When you select a recipe for change or display, the system displays the recipe version valid on the key date.If you change a recipe with a change number, the system uses the valid-from date in the change master record as the key date. The new change status becomes valid from that date. If you change a master recipe without a change number, the change is valid for the entire validity period of the change status selected.

The default value for the key date is the current date.

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Changerequest

-Change number- Change type

Approval procedure for changes

System status network / user status profile

Authorizations for user status

Workflow link

FunctionsFunctions

Advance planning / validity period of changes

Def. of object types (f.ex. recipes, BOMs, etc.) that canbe changed

Def. of objects that can be changed (f.ex. recipe "REC-101”)

Def. of authorizations required for change master recordmaintenance

Complete documentation of changes

Engineering Change Request / Order

Engineering change orders have the functionality of change master records. However, they comprise the following additional functions:

The possibility of triggering a workflow task such as sending a message to the person responsible at a particular processing stageA procedure for the approval and release of changes during which an unapproved engineering change request is converted into an approved engineering change order.The assignment of a user status profile to extend the system status networkThe assignment of authorizations for user statuses

You can create, change, or display a master recipe with reference to an engineering change order. The valid-from date of the engineering change order is then used as the key date. The engineering change order must meet the following requirements:

It must have been approved and contain at least one object management recordIf a corresponding change rule has been maintained for the recipe, the change type of the object management record must also be identical to that in the recipe header.To maintain component assignments, material quantity calculation, and the bill of material from within the recipe, you also need an object management record with approved changes for the bill of material.

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User status profileWorkflow tasks

Change number Change type for change header Valid-from date Authorization group Reason for change

Master recipes Material BOMs Documents

For example, master recipe "Colors" Change type for object Reason for change

Change headerChange header

Object typesObject types

Object mgmt recordsObject mgmt records

Structure of an Engineering Change Request

General header data of the change request:The change request is identified by the change number you enter.The change type controls the change process for the entire order using a system status profile. You can assign a user status profile and workflow tasks for different processing steps to the change type.The valid-from date specifies the date on which the changes come into effect.By entering an authorization group, you can define that a special authorization is required to maintain the engineering change request.Entering a reason for the change enables you to document planned changes fully.

Allowed object types:You must define the object types that may be changed with the engineering change request. These include, for instance, master recipes, material BOMs, and material master records.

Creating object management records for objects you want to change:You must create an object management change record for every object you want to change using the engineering change request. An example for a change object would be a certain master recipe.You maintain a change type for each object management record. The change type controls the change process for the specific object.Entering a reason for the change for an object management record enables you to document planned changes of a particular object fully.

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Changemaster record

- Change number

Change type

System status

User status

Object mgmt records

Generating obj. mgmt records

Entering valid-from date

Changing objects

Eng. changeorder/request

- Change number- Change type

-

-

-

X

X

Immediately

Immediately

X

X

X

X

-

Bef. conversion

Aft. conversion

Comparison of Change Master Records and Engineering Change Requests / Orders

In contrast to the engineering change requests/orders, you may not enter any change types for change master records. There is no system status network for change master records.

Since object management records are not automatically generated for the engineering change request/order, the icon for this does not appear in the object type overview.

You cannot use the automatic generation function here, because the engineering change request/order is to control the business processes of requesting, inspecting, and releasing changes for certain assigned objects. This excludes an implied assignment during object change itself (by using the change number).

Note: The example in the graphic corresponds to the default setting for the engineering change request/order.

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None

With change number

With engineering change order (without change type)

With engineering change order (with change type)

1

3

2

Change ruleChange rule

Changing Master Recipes

In process industries, requirements for documentation and checking of master recipes vary widely depending on the branch of industry and the product. They range from fairly unrestricted maintenance of recipes to detailed planning, documentation and even strict approval procedures.

To meet these requirements, the R/3 System offers various types of recipe maintenance. You can enter a change rule in the recipe to specify the maintenance procedure that is to be used for a recipe (General View screen).

You can create or change master recipes as follows:Without a change number:All you need is an authorization for the corresponding recipe transactions. Changes are valid for the entire validity period of the selected change status.With a change number:By using a change master record, you can combine planning and execution when creating and changing related objects such as recipes, materials, and bills of material. The validity date is specified using a change master record (synonymous with change number). A new version is created for all changed recipe objects (for example, operation, relationship).With an engineering change order:With engineering change orders, the functionality of the change master record is enhanced by a detailed approval procedure. By entering a change type, you can specify that the approval procedure must be carried out in a specific user-defined way.

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As soon as you have assigned a change rule to a recipe and thus defined that it is subject to a specific change procedure, this recipe is locked for all change procedures that are less restrictive. To revoke the restriction, you must change the recipe in the way specified in the change procedure.

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Change not necessaryChange not necessaryChange not possibleChange not possible

Errors in changeErrors in change

Errors correctedErrors corrected

Objectchange

Change released

Change completed

Change possible

ObjectObject

System Status Network Object

The procedure for approving and releasing engineering change requests or orders is controlled via links between statuses and business transactions. The statuses mark particular processing statuses during the approval procedure. They include both fixed system statuses and user-defined user statuses. You can proceed from one status to the next by carrying out a business transaction.

The predefined status network for the object management record is valid for all objects to be changed that are of the object type material, document, BOM, and task list.

You can easily change the status from Change possible to Change not possible or Change not necessary in any direction, as shown in the graphic.

Only the status Change possible requires further consideration of the object change and the setting of another status. When at least one object management record contains this status, the request that belongs to it must be converted to an order.

After you make the setting Change complete, the change can be set to Errors in change. In this case, the errors must be corrected before the changes can be released.

You can extend the status network to include user status.

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EngEng. change request. change request

EngEng. change order. change order

Check

Checked

Approve

Convert

Reject request

Withdrawapproval

Requestcomplete

Request notcomplete

Complete

Release

System Status Network for Engineering Change Requests / Orders

An extensive, pre-defined status network exists for the engineering change request/order (process control).

You are only allowed to assign object management records to the order before you set the status Checked.

When all assigned object management records have the status Change possible or Change not required, the request can be set to Checked and Approved and can be converted to an order.

After setting the status to Checked or Approved, the request can be rejected. After settting the status to Approved, the approval can be withdrawn. If at least one object is to be changed, the request must be converted to an order. Before converting, you must maintain the valid-from date of the request. After converting, you can set the request to Not complete. In this case, you must set the request to

Complete again in order for the process to continue. When the order and the object management record have been released, the object can be changed. You can lock the request/order at any time and withdraw the lock again. You can extend the status network to include user statuses.

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(...)• Change objects (for example, recipe "COLORS")

Create engineering change request

Object changes (f.ex. for recipes "COLORS") possible

Recipe approval (f.ex. for recipe "COLORS") granted

Complete and release changes/ engineering change order

Convert change request into change order

Approve changes

Check planned changes

Recipe Approval (General Procedure)

The change procedure using an engineering change request comprises three main steps:Creating an engineering change requestChecking an engineering change request and converting it into an engineering change orderChanging objects and completing the change

For a master recipe marked with change type With engineering change order, this process represents an approval procedure. Once the procedure has been released, the maintained recipe is marked as Approved recipe for the change period defined by the valid-from date of the change request.

Recipes that have already been approved but are changed using another change order are considered unapproved during the period between the conversion and release for the change period defined by the valid-from date. Approval is granted when the change order is released.

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Check by plant mgmt

Check request Check object(f.ex. recipe "COLORS")

(User status) Check by chemistCheck by qual. assurance

Changes possibleReq. checked

Approve request

Convert requestObjects can be changed(f.ex. recipe "COLORS")

Status of change header Status of change objects

Recipe Approval (Statuses I)

The procedure for approving and releasing engineering change requests or orders is controlled via links between statuses and business transactions. The statuses mark particular processing statuses during the approval procedure. They include:

A fixed network of system statusesCompany-specific user statuses

You can proceed from one status to the next by carrying out a business transaction. SAP has defined a standard approval procedure, which has been implemented via a network of system

statuses:1. An engineering change request is created that describes planned changes to various objects,

including master recipes.2. The planned changes to the individual objects are checked and marked as possible or

unnecessary.3. After the check has been concluded, the engineering change request is approved and converted

into an engineering change order. Now you can make the changes, that is, the master recipe can be maintained with reference to the engineering change order.

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Complete order Complete changes

Check by chemistCheck by qual. assurance

Release changes

Check by plant mgmt

Convert requestObjects can be changed(f.ex. recipe "COLORS")

Release order

Status of change header Status of change objects

Master recipe is approved

Recipe Approval (Statuses II)

4. After the changes to all objects have been made, the entire engineering change order is completed.

5. The engineering change order is released. The recipe has now been approved and can be used to create orders requiring an approved recipe. If the approval procedure defined by SAP does not meet all your requirements, you can add company-

specific checks at the change order header or change object level. To do so, assign a change type with a corresponding user status profile to the engineering change request or the change object.

Status profiles are defined and assigned to change types within Customizing for engineering change management. They contain company-specific user statuses. In the status profile, you link these user statuses to the business transactions you carry out, thus inserting them in the existing network of system statuses.

You can specify that a special authorization is required to set or delete a user status.

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Particular business transactions:Digital signature required

Special approval procedure requiredSpecial approval procedure required

Unique and forgeryUnique and forgery--proof proof user identificationuser identification

Documentation:Documentation:name of user, signed transaction, date, timename of user, signed transaction, date, time

Digital Signature (I)

You can specify that a user must execute a digital signature to be able to carry out particular business transactions.

The digital signature enables you to meet the security requirements laid down in the Good Manufacturing Practices (GMP) with regard to the execution of these transactions. The digital signature ensures that:

A transaction can only be carried out by users with a special authorizationThe user identification is unique and forgery-proofThe name of the user is documented together with the signed transaction and the date and time, and cannot be falsified afterwards.

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Digital signatureDigital signature

PPPP--PI:PI:

PI sheet Batch record

Eng. change request / order

Engineering Change MgmtEngineering Change Mgmt

Inspection results recording Usage decision

QM:QM:

Digital Signature (II)

The digital signature can be implemented for the following areas: Quality management

Saving inspection results for an inspection lotRecording and changing the usage decision for an inspection lot

Engineering change managementChanging the status of an engineering change order/requestReleasing an engineering change order

PP-PICompleting a phase in the PI sheetAccepting invalid values within input validations in the PI sheetApproving a batch record

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PPPP--PI:PI:

PI sheet:Customizing for control recipe destination DS (digital signature)Batch record approval: Digital signature always required

PI sheet:Customizing for control recipe destination DS (digital signature)DS (digital signature)Batch record approval: Digital signature always requiredDigital signature always required

Engineering Change Management:Engineering Change Management:

Customizing: Change types Customizing: Change types

QM:QM:

Material authorization groups Digital signature for results recording Digital signature for usage decision

Material authorization groups Digital signature for results recordingDigital signature for results recording Digital signature for usage decisionDigital signature for usage decision

Activating the Digital Signature

To specify that a digital signature is required for the above mentioned transactions, you must have activated the function in the relevant application. This can be done in the following ways:

In PP-PI:For completing a phase as well as for accepting invalid input values in the PI sheet, set the DS (digital signature) indicator in Customizing for Control Recipe Destinations.When approving a batch record, the user must always execute a digital signature.

In engineering change management:To save status changes of the engineering change request before order processing, set the Dig. sig. indicator in Customizing for change types for object master records.For change order release, set the Dig. sig. indicator in Customizing for change types for object master records.

In QM:For inspection results recording, set the Digital signature for results recording indicator in the material authorization groups.For the usage decision, set the Digital signature for usage decision indicator in the material authorization groups.

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Engineering Change Management, Recipe Approval: Unit Summary

You can use change master records to plan the validity period of changes.

Change orders also facilitate special approval procedures for changes.

The approval and release of engineering change orders takes place via the status profile.

You can use the digital signature to ensure that particular transactions are only carried out by authorized persons.

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15.25 Exercises

Unit: Engineering Change Management

Topic: Change Numbers and Recipe Approval


Create change numbers/master records

Go through the recipe approval process

Create engineering change requests / engineering change orders


A suitable production version with a master recipe and BOM for process manufacturing already exist.

To ensure regulatory compliance, you must follow an existing status profile for recipe approval to change the master recipe.

As the person responsible, specify the changeability of your master record accordingly.

1-1 Creating change master records (change numbers)

Create two change master records to change a master recipe.

Create Change Master: Initial Screen

Change number: AEND_01_##

(or)AEND_02_##

Type: Change master

Function: Without release key

Create Change Master Record: Change Header screen

Description: Change number of group ##

Valid from: Today + 1 week for AEND_01_##

Today + 2 weeks for AEND_02_##

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Change no. status: 01 ‘active’

After you release the data, the Create Change Master: Object Types screen appears.

Specify that your master recipes and BOMs are changeable objects.

Edit -> More -> Object sub-types

Object type specification: Task list and BOM

Set the following indicators for the object types "Master recipe" and "Material BOM":

– Actv.

– Object

– MgtRec

Note: By setting these indicators, you define that

i) Master recipes and material BOMS (and production versions) can be changed with this change number

ii) Object management records are automatically created for the changed objects

Save your change master records.

1-2 Changing master recipe objects with a change number

1-2-1 Change the master recipe T-DET1## with the change number AEND_01_##.


Task list group: T-DET1##Choose Assign change number.

Change number: AEND 01

Choose Recipe.

Change the charge quantity range of your recipe to 1,000 -40,000 L.

Display the administrative data for the recipe header.

Save your recipe and your production version.

1-2-2 Change your master recipe T-DET1## with the change number AEND_02_##.

Enter the original charge quantity range (1,000 -20,000 L).

Display the administrative data.

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Save your recipe and your production version again.

1-2-2-1 Display the header data of the recipe T-DET1## and the administrative data for the following key dates:

– Today

– Today +10 days

– Today + 20 days

1-3 Documentation of changes

1-3-1 Documentation in the change master record

Display the change master record AEND_01_##.

Which master recipe was changed with the change number, that is, for which master recipe was an object management record generated?

_____________________

Change number Display

Choose All objects.

Note: You find details on an object management record by double-clicking each object. Detailed descriptions of changes can be defined for an object management record.

1-3-2 Recipe changes

Which changes were made to the recipe header of recipe T-DET1##?

Master recipe menu / Reporting Recipe -> Recipe changes

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Task list type: 2

Plant: 1100

Recipe group: T-DET1##

Recipe: 1

Change documentation for the following object: recipe header

Program -> Execute

______________________________________

______________________________________

______________________________________

1-4 Recipe approval

1-4-1 Change rule

1-4-1-1 Select the production versions for recipe T-TAB##. Open the master recipe for production version 0001 of material T-HT2## on the key date "Today".

Which processing mode (display or change?) appears?

__________________________________

Find out the meaning and function of the “Change rule“ and “Change type“ fields using the F1 help in the recipe header.

Which change rule or change type is set?

Change rule:

Change type:

Save the recipe.

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1-4-1-2 Try to access the recipe in the change mode.

Master Data Master Recipes Recipe and Material List Change

Why can you only display the recipe data and not make any changes?

_____________________________________________

_____________________________________________

Notice the message in the status bar. Get more information on error diagnosis and how to proceed further by double-clicking this message.

1-4-2 Creating an engineering change request

1-4-2-1 In engineering change management, create change request REQUEST## of the change type 100, "change of recipes".

Make the following entries on the Create Engineering Change Request: Change Header screen:

Description: Recipe change T-TAB##

Valid from: Today + 1 week

Change no. status: 01 ‘active’

Reason for change: Display SOP in ProdInst for T-TAB##

Allow the changeability of the object types “Master recipe“ and "Material BOM".

Edit MoreObject sub-types/ Task list and BOM indicators

Set the Actv. indicator and Object indicator for the object types Master recipe and Material BOM. Delete all indicators set for other object types.

Define the recipe T-TAB## and the BOM for material T-HT2## as changeable objects.

Choose Objects.

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TL type TL group Description Change type

2 T-TAB##Add new

proc. inst. for SOP call100

Materials tab

Material Plant BOM usg. Description Change type

T-HT2## 1100 1 No change see above

Define the following long text for the object management record referring to the the planned changes to the recipe:

Task list tab

Choose Details for T-TAB##

Choose Object long text

Due to a new safety rating of material T-RD1##, you must be able to call up the Standard Operating Procedure (SOP) from the archive system in the PI sheet for phase 110. An appropriate process instruction must be added for phase 110. The change must be valid from the date “today + 1 week“.

1-4-2-2 Which statuses are set for your change objects?

In each object management record for the recipe or BOM, choose Status mgmt.

System status:

____________________________________

User status:

____________________________________

Which statuses are set for the change request?

Choose Change header and then Status mgmt.

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System status:

____________________________________

User status:

____________________________________

Save your change request.

1-4-3 Try to change your recipe T-TAB## (group counter 2, production version 2) with reference to this request.

Which error message do you receive?

______________________________________________________

Display the message log. What is the message text for the error message?

______________________________________________________

Find out more about the reasons for the error and how to fix it by double-clicking the error message.

______________________________________________________

______________________________________________________

1-5 Checking, approving and converting the engineering change request

1-5-1 Set the status Check request for the engineering change request.

Engineering Change RequestChange / Choose Set status / Choose Check request.

1-5-2 What additional system status is set for the engineering change request?

____________________________________

1-5-3 What additional system status is set for the engineering change objects?

____________________________________

Choose Objects.

Select objects.

Choose Detail and then Status mgmt.

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Choose Previous / Next object.

1-5-4 Can you set the object system status Change possible for your recipe or BOM at the moment?

____________________________________

In the object management record of the recipe or BOM, choose Set status.

1-5-5 Before you can set the status, the user status that is set must be withdrawn by the authorized persons.

Withdraw each user status.

Choose Status mgmt.

1-5-6 Set the object status to Change possible.

1-5-7 Which status is additionally set for the change header?

_____________________________________

1-5-8 Set the system status to ECR checked.

1-5-9 The request must now be approved and converted to an engineering change order before the engineering change object can be edited. Before you can set the status, the user status that is already set must be withdrawn by an authorized person.

Withdraw the user status and set the system status Approve request and Convert request.

Save your engineering change order.

1-6 Changing with an engineering change order

Change your master recipe T-TAB## (group counter 2, production version 0002) with reference to your engineering change order ORDER##.

Add the process instructions DOC_SHOW of type 6 “Dynamic function call“ for phase 11.

Save your recipe and the production version.

1-7 Closing and releasing object changes and engineering change orders

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Call up your engineering change order in the change mode.

Which statuses does the engineering change order have?

_____________________________________

_____________________________________

_____________________________________

_____________________________________

Which statuses do the characteristics have?

_____________________________________

_____________________________________

_____________________________________

_____________________________________

1-7-1 Set the status Complete change for the engineering change objects.

In the meantime, save your engineering change order and try to change your recipe T-TAB## with reference to the engineering change order.

Find out more about the system messages created while doing this.

1-7-2 Continue to process your engineering change order.

Which system statuses do the engineering change objects have now?

_____________________________________

_____________________________________

_____________________________________

Which user status was set when you closed?

_____________________________________

_____________________________________

_____________________________________

The engineering change object can only be released after being inspected by the responsible areas defined by the object user status. These authorized users withdraw their user status after inspection, and the object can then be released.

Withdraw the user status for the engineering change object and set the object system status Release change.

1-7-3 Set the system status Close for the engineering change order.

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Which system statuses does the engineering change order have now?

_____________________________________

_____________________________________

_____________________________________

Which user status was set when you closed?

_____________________________________

The engineering change order and corresponding approval can only be released after being inspected by the responsible area defined by the order user status. An authorized person withdraws the user status after inspection and releases the order.

Withdraw the user status for the order and set the order system status to Release change.

Save your engineering change order.

1-8 Status report on engineering change order

Generate a detailed status report on your engineering change order.

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15.26Solutions

Unit: Engineering Change Management

Topic: Change Numbers and Recipe Approval

1-1 Creating change master records (change numbers)

Create two change master records to change a master recipe.

Production - Process -> Master Data -> Engineering Change Management Change Number -> Create

Specify that your master recipe is a changeable object.

Edit -> More -> Object sub-types

Object type specification: Task list.and BOM

1-2 Changing master recipe objects with change numbers

1-2-1 Change the master recipe T-DET1## with the change number AEND_01_##

Production versions

Select Production version.

Choose Assign change number.

Enter the change number and choose Enter.

Choose Recipes.

Recipe header tab

Enter the new charge quantity range


The recipe is now assigned the change number with its validity range.

Save the recipe and production version.

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Choose Refresh.

1-2-2 same as in 1-2-1

1-2-2-1 Select production version.

Choose Recipe.

Enter key date.

Choose Display recipes.

Recipe header and Administrative data tab

1-3 Documentation of changes

1-3-1 Documentation in the change master record

Display the change master record AEND_01_##.

Which master recipe was changed with the change number, that is, for which master recipe was an object management record generated?

T-DET1##

Change number Display

Choose All objects.

1-3-2 Recipe changes

Which changes were made to the recipe header of recipe T-DET1##?

Changes were made to the lot size (Charge quantity range) using the change number from part 1-1.

1-4 Recipe approval

1-4-1 Change rule

1-4-1-1 Production versions for master recipe T-TAB##


Choose Recipes.

You are in the display mode.

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Recipe header tab

Change rule: “With engineering change order" (with change type)

Change type: 200

1-4-1-2 Try to access the recipe in the change mode.

Why can you only display the recipe data and not make any changes?

The change rule 3 (= with engineering change order) does not allow changes to the recipe without the entry of an engineering change order.

1-4-2 Creating an engineering change requestProduction-Process -> Master Data -> Engineering Change Management -> Change Number -> Create

1-4-2-1 In engineering change management, create change request REQUEST## of the change type 100.

Enter data and press Enter.

Allow the changeability of the object types “Master recipe“ and "Material BOM".

Edit MoreObject sub-types/ Set Task list and BOM indicators.

Choose Copy.

Set the "Active" and "Object" indicators for the material BOM and master recipe and choose "Enter".

Define the recipe T-TAB## and the BOM for material T-HT2## as changeable objects.

Choose Objects.

Task list tab.

Enter data for T-TAB## and press Enter.

Material BOM tab

Enter data for material T-HT2## and press Enter.

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Task list tab

Select task list group T-TAB##.

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Choose Detail view.

Choose Long text object.

Enter text, save and go back.

1-4-2-2 Which status types are set for your change objects?

In each object management record, choose Status mgmt.

System status:

Created

User status:

CHEM: Check by chemist

QUAL: Check by quality assurance

PROC: Check by process technology

Choose Back.

Which statuses are set for the change request?

Choose Change header and then Status mgmt.

System status:

Created

User status:

Check by plant management

Save engineering change request

1-4-3 Try to change your recipe T-TAB## (group counter 2, production version 0002) with reference to this request.

Production versions

Select Production version 0002.


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Which error message do you receive?

The change number was not assigned to all entries you have selected. Incorrect entries are still selected.

Display the message log. What is the message text for the error message?

System status: ECR is not yet approved

Find out more about the reasons for the error and how to fix it by double-clicking the error message.

The system checks the system status of the engineering change request. The engineering change request must be approved and converted to an engineering change order.

1-5 Checking, approving and converting the engineering change request

Check

1-5-1 Set the status Check request for the engineering change request.

Engineering Change Request Change / Choose Set status. / Choose Check request.

Choose Continue.

1-5-2 What additional system status is set for the engineering change request?

Choose Status mgmt.

Status: Check ECR

Choose Back.

1-5-3 What additional system status is set for the engineering change objects?

Choose Objects.

Select both objects.

Choose Detail view.

Choose Status mgmt.

To navigate between the individual objects:

Choose Previous / Next object.

Status: Inspection request for ECR

Choose Back.

(C) SAP AG LO305 41

1-5-4 Can you set the object system status Change possible for your recipe or BOM at the moment?

Choose Set status.

No

Choose Continue.

1-5-5 Choose Status mgmt.

Remove all indictors for the user status for both objects

Choose Back.

1-5-6 For both objects:

Choose Set status for status Change possible.

Approval and conversion

1-5-7 Which status is additionally set for the change header?

Choose Change header.

Choose Status mgmt.

Status: All objects checked

Choose Back.

1-5-8 Set the request system status to ECR checked.

Choose Set status.

Choose Req. checked.

Choose Continue.

1-5-9 Choose Status mgmt.

Remove indicator for user status

Choose Back.

Choose Set status.

Choose Approve request.

Choose Convert request.

Choose Continue.

Save order

1-6 Changing with an engineering change order

Production versions

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Select Production version 0002.


Choose Recipes.

Operations tab

Select phase 11 and choose Process instructions.

Add process instruction DOC_SHOW.

Save recipe and production version.

1-7 Closing and releasing object changes and engineering change orders

Call up your engineering change order in the change mode.

Change Number Change

Which statuses does the engineering change order have?

Choose Status mgmt.

All objects checked

ECR checked

ECR approved

ECOP: ECO to be processed

Choose Back.

Which statuses do the characteristics have?

Choose Objects.

Select both objects.

Choose Detail view.

Choose Status mgmt.

Created

Object: Change possible

Object: To be processed

Object: In preparation

Choose Back.

1-7-1 Set the status Complete change for the engineering change objects.

In the object management record: Choose Set status.

Choose Complete changes.

(C) SAP AG LO305 43

Choose Continue.

(C) SAP AG LO305 44

1-7-2 Continue processing your engineering change order.

Which system status does the engineering change object T-TAB## have now?

In the object management record:

Choose Status mgmt.

Created

Object: Change possible

Object: Change completed

Which user status was set during when you closed?

CHEM: Check by chemist

QUAL: Check by quality assurance

PROC: Check by process technology

For the object in status management:

Remove all indictors for the user status

Choose Back.

Choose Set status.

Choose Release changes.

Choose Continue.

1-7-3 Set the system status Complete order for the engineering change order.

Choose Change header.

Choose Set status.

Choose Close.

Choose Continue.

Which system statuses does the engineering change order have now?

Choose Status mgmt.

All objects checked

ECR checked

ECR approved

ECO confirmed

(C) SAP AG LO305 45

ECO completed

All objects released

Which user status was set while closing?

Check by plant management

Remove indicator for user status

Choose Back.

Choose Set status.

Choose Release order.

A message appears that the engineering change order has been released.

Choose Continue.

Save order

1-8 Status report on engineering change order

Choose Change Number Change

Choose Enter. If a warning appears, confirm with enter.

Environment Reporting Status Report

or

Choose Status report for the system status.

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16

SAP AG 1999

Life cycle of a process order

Information about further courses

Contents:


(C) SAP AG LO305 1

16.2

SAP AG 1999


Summary and Conclusion: Unit Objectives

Create a process order for a material

Carry out system-aided batch determination and resource selection

Release the order, create a control recipe, and send it

Maintain the PI sheet and send messages that have been created

(C) SAP AG LO305 2

16.3

SAP AG 1999

PP-PI Overview


Introduction


Batches



Production Version






1111

22

33

11

55

66

77

88

99

1010

1212

1313

1414

1515

Materials44


1616 Summary and Conclusion

Overview Diagram 16

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16.4

SAP AG 1999

Summary and Conclusion: Business Scenario

You have made the settings and maintained the data necessary for the process manufacturing of the new product in the R/3 System.

As the person responsible, create a process order and have the corresponding PI sheet maintained by a process operator.

(C) SAP AG LO305 4

16.5

SAP AG 1999

PCS

Process controlsystem (autom.)

PI sheetLaboratory

information syst.

LIMS PI sheet(manual)

Master recipe

Resource

MaterialMaterial

Master dataMaster data

Production planningProduction planning

Qualitymanagement

Processplanning/

orders

Processmanagement

Process datadocumentation/

evaluation

Functions of PP-PI

PP-PI comprises the following functional areas :Resource management: The PI-specific master data of resources describes all means of production and persons involved in the production process.Master recipe management: The PI-specific master data of master recipes describes the manufacture of one or more materials in one production run without relating to a particular order. Master recipes are the basis for process orders.Process planning comprises the planning of process orders. Process orders are created on the basis of master recipes. They describe and monitor the actual production process.Process management coordinates the transfer of data between PP-PI and the process control level. It can be used in fully automated, partially automated, and manually operated plants.Process data documentation and evaluation enables a detailed documentation and evaluation of all planned and actual values of a process.

PP-PI is integrated with, for example:R/3 Quality Management. Via a special interface, external laboratory information systems (LIMS) can be linked to R/3 QM.The higher-level planning components of R/3. Production requirements for PP-PI are created in R/3 Material Requirements Planning. Via a special interface, you can also transfer requirements from an R/2 System or an external planning system to PP-PI.

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The master data and functions of R/3 Materials Management (such as material, inventory management).

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16.6

SAP AG 1999

•Material master•Bill of material

•Proc. units•Personnel

•Automatic control•Manual control (PI sheet)

Manually

QMQM

MMMM

PPPP

PP-PIPP-PI

Planned orderPlanned orderProduction reqmts

MaterialsMaterialsMaster recipeMaster recipe Process orderProcess order

ResourcesResources

Process data documen-tation & evaluation Process managementProcess management


Control recipe:Control recipe:proc. instructionsproc. instructions

Process controlProcess controlsystemsystem

Processcontrol level

Data Flow in PP-PI

A production process is triggered by production requirements. Production requirements are created in material requirements planning in the form of planned orders. Planned orders define the basic dates and planned production quantities.

During process planning, planned orders are converted into process orders. The basic dates and production quantities are copied from the planned order. The actual production dates are calculated using the basic dates. You can also create a process order manually.

A process order provides a detailed description of the actual production of one or more materials in one production run. It is the main control instrument in production, describing and monitoring all planned and actual data relating to production.

A master recipe is used as the basis for a process order. It defines, for example, the planned resources and material components.

After a process order has been released for production, the process instructions maintained in the order are bundled into control recipes by process management. The control recipes are either transferred to a process control system via a specific interface or are displayed online in the form of a process instruction sheet (PI sheet) that can be read and maintained by process operators.

Process management in turn receives process messages from the process control level and transfers them to various destinations. For instance, it is possible to record confirmations for the process order, transfer actual values of the process to functions for process data documentation and evaluation, post

(C) SAP AG LO305 7

material consumptions or production yields as goods movements and transfer quality data to Quality Management results recording.

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16.7

SAP AG 1999

Production reqmnts

Costs


Proc. orderProc. order


Resourceassignments

Process ordersettlement

Process data documentation

Archiving / Deleting

Proc. messages to diff. destin.

In-process qualityinspections

Orderconfirmations

Process ordercreation

Scheduling

Cap.rqmts planning

Material availability check

Process order release

Creating & download. control recipes

M

Or

Ord

erder

closingclosing

Pro

plan

nin

gcess

R P

gege

Pro

ces

sP

roc

ess

ProcessProcess

ord

ord

exeexe

cutcut

manamanaion /

ion /m

ent

men

terer

Materialcomponents

RelationshipsRelationships

Material withdrawals

Good receipts PhasesPhases

Life Cycle of a Process Order

The graphic shows the main steps that are carried out for controlling process manufacturing in the R/3 System.

The process order is the main instrument for executing and monitoring production. The procedure of process order management can be divided into the following steps:

Process planningProcess order execution/Process managementOrder closing

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16.8

SAP AG 1999

Production reqmnts

Costs


Proc. orderProc. order


Resourceassignments

Archiving / Deleting

Proc. messages to diff. destin.

In-process qualityinspections

Orderconfirmations

Process ordercreation

Scheduling

Cap.rqmts planning

Material availability check

Process order release

Creating & download. control recipes

M

Ord

Ord

derder

Pro

c.P

roc.

closingclosing

Pro

plan

nin

gcess

R P

gege

Pro

ces

sP

roc

ess

ProcessProcess

ord

ord

exeexe cut

cutmanamanaion /ion /

men

t

men

terer

Materialcomponents

RelationshipsAnordnungs- beziehungen

Material withdrawals

PhasesPhases

LO310LO310Detail Functions inDetail Functions in

Process ManufacturingProcess Manufacturing

Order Processing - Further Information

Process ordersettlement

Good receipts

Process data documentation

Further information on this topic is provided in the course LO310 "Detail Functions in Process Manufacturing".

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16.9

SAP AG 1999

ExecutionExecutionProcessProcessmanagementmanagement

ProcessProcesscontrolcontrol

And otherAnd othermessagemessage

destinationsdestinations

ProcessProcessplanning

Process Process control control systemsystem

PI sheetPI sheet

LO315LO315Process ManagementProcess Management

Process Management - Further Information

Process order

Control recipes

Process messages

Further information on this topic is provided in the course LO315 "Process Management".

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16.10

SAP AG 1999

50

40

30

20

10

Integration with Quality Management

LO955LO955Batch ManagementBatch Management

LO705LO705Quality InspectionsQuality Inspections

Batch Management in the Logistics ProcessProduction SalesProcurement

Ware-house

Process/productionorder

Ware-house

Salesorder

AB

AB

Warehouse management Warehouse management

A A

A

KMTKMT

Batch assignment

Batch determination

Batch assignment

Batch determination

Purchaseorder

LO721LO721QM in Process QM in Process ManufacturingManufacturing

QM and Batches - Further Information

Inspection specificationsInspection specificationsConcentrationConcentrationpH valuepH valueViscosityViscosity

R/3 QM insp. lot:R/3 QM insp. lot: Insp. char.Insp. char.

QMQM--IDIIDI

Ext.Ext. Labor. information systemLabor. information system(LIMS):(LIMS): analyt. specificationanalyt. specification

Insp. results recording20 %7,3 100 cP

R/3 QM insp. lot: char. values

QM-IDI

LIMS: analytical results

Further information on the topics "Quality Management" and "Batch Management" are provided in the courses LO705 "Quality Inspections" and LO955 "Batch Management".

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16.11Summary: Exercises

Unit: Summary


Create and process orders

Carry out batch determination and resource selection

Generate a control recipe and a PI sheet

Work with the message monitor

You have made the settings and maintained the data necessary for the process manufacturing of the new product in the R/3 System.

As the person responsible, create a process order and have the corresponding PI sheet processed by a line operator.

Note: The following exercises will illustrate the complete execution of a process order based on the master data created in the previous exercises.

1-1 Creating process orders

Create a process order of the order type PI01 for material T-FD1## (detergent) in plant 1100.

Total quantity: (for example) 10000L


Choose Enter and pay attention to the messages in the status bar. The master recipe T-DET1## (detergent production) is copied with the material list and the process order is scheduled.

On the Operation Overview and Material List screens, check whether the data from the master recipe T-DET1## has been copied correctly.

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1-2 System-aided batch determination

Note:

In the previous exercises, you posted batch stocks for your material component T-RD1## which is to be handled in batches. The batches are classified with the class 023_14 (detergent production) of the class type 023 (batch). The characteristics M100 (concentration) and M200 (density) are assigned to class 023_14 to which you assigned the corresponding batch characteristics.

You also classified the BOM item 0010 T-RD1## in the BOM for material T-FD1## with the same class. By doing this, you defined selection conditions for a system-aided batch determination.

Execute batch determination for component T-RD1## in the order.

Pay attention to the messages.

Assign a selected batch.

Save your order and write down the order number. __________________.

1-3 System-aided resource selection

Note:

In the previous exercises, you classified your reaction vessel with the class REAC_## (Reaction vessel) of the class type 019 (Work center class) and defined specific characteristics for these resources by assigning them values.

The resource T-DTG1## that is assigned to operation 200 only serves planning purposes (task list usage C## Recipe until release group##). An order cannot be released with this resource. Before the release of an order can take place, a planning resource must be replaced with a suitable real resource.

You also classified operation 200 with the class REAC_## and, by assigning the corresponding values to the characteristics, defined selection conditions for a system-aided resource selection of a suitable reaction vessel. The resource network is considered at the same time.

Execute a resource selection for operation 200.

Select a resource.

1-4 Releasing a process order

Release your order.

1-5 Generating a control recipe

(C) SAP AG LO305 14

Generate a control recipe for the order.

Save your order.

1-6 Sending a control recipe

Send your recipe in the control recipe monitor.

1-7 Maintaining the PI sheet

Find and maintain the PI sheet.

Confirm the start and finish of phase maintenance with your signature. Sign with your user PI## and confirm with your.

Read the notes that have been prepared in the PI sheet.

Confirm the material withdrawal quantities of the raw materials T-RD1## and T-RD2##. Use the material information that is listed and F4 as help. Do the same for the withdrawal of the raw materials T-RD3##, T-RD4##, and T-RD5##.

Confirm the produced quantity of the product T-FD1##.

Set the PI sheet to complete after the last signature.

PI sheet -> Set to complete

1-8 Sending process messages

In the message monitor, send the process messages that were created during the maintenance of the PI sheet.

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1-9 Check withdrawn raw material quantities and time confirmations

Check the withdrawn quantities of raw materials in your process order. Also check the time confirmations for the order.

(C) SAP AG LO305 16

16.12Solutions

Unit: Summary

1-1 Creating process orders

Create a process order of the order type PI01 for material T-FD1## (detergent) in plant 1100.

Logistics -> Production - Process -> Process Order Process Order -> Create -> With material

On the Operation Overview and Material List screens, check whether the data from the master recipe T-DET1## has been copied correctly.

Choose Operations.

Choose Materials.

1-2 System-aided batch determination

Execute batch determination for component T-RD1## in the order.

In the material list:

Choose Trigger batch determination for component T-RD1##

For a batch found:

Choose Copy.

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1-3 System-aided resource selection

Execute a resource selection for operation 200.

Process order Change

Operation overview

for operation 200:

Choose Execute resource selection.

Select a resource.

1-4 Releasing a process order

Release your order.

Choose Release.

1-5 Generating a control recipe

Generate the control recipe for the order.

Choose Generate control recipe.

1-6 Sending a control recipe

Send your control recipe in the control recipe monitor.

Process Management menu Control recipe -> Control recipe monitor

(C) SAP AG LO305 18

1-7 Editing the PI sheet


Process Management PI sheet Find

Set the PI sheet to complete after the last signature.

PI sheet -> Set to complete

1-8 Sending process messages

In the message monitor, send the process messages that were created during the maintenance of the PI sheet.

Process management Message -> Message monitor

1-9 Check withdrawn raw material quantities and time confirmations

Check the withdrawn quantities of raw materials in your process order. Also check the time confirmations for the order.

Process order -> Display

Material List

For the material components, choose Material -> Material details

Operation Overview

For the phases, choose Operation -> Operation details

Dates group box.

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