Contents at a Glance PART I Production Planning Core Concepts PART II Configuration Specifics for Manufacturing Types

Transcription

1 at a Glance PART I Production Planning Core Concepts 1 Introduction Organizational Structures in SAP ERP PART II Configuration Specifics for Manufacturing Types 3 Configuration Basics of Discrete Manufacturing Configuration Basics of Process Manufacturing Configuration Basics of Repetitive Manufacturing PART III Production Planning Workflow by Production Type 6 Production Planning for Discrete Manufacturing Production Planning for Process Industries Production Planning for Repetitive Manufacturing PART IV Production Planning Workflow Tools 9 Sales and Operations Planning SAP Demand Management Material Requirements Planning Long-Term Planning PART V Optimizing Production Planning 13 Special Procurement Types Capacity Requirements Planning Classification Co-Products and By-Products in Production Processes Digital Signature PART VI Monitoring and Evaluation 18 Early Warning System Reporting in SAP Integration of Production Planning with Logistics Functions

2 Dear Reader, In manufacturing, there s a maxim: You can have it cheap, fast, or good. Pick two. In the publishing industry, where micro-level editing is seemingly endless, we usually say, It s either published or perfect. Pick one. For an editor, then, there is a unique pleasure in working on a second edition. It offers a chance to right past editorial wrongs (the missing comma on page 438 or the typo on page 822 that sneaked into the first edition). We can take the opportunity to re-examine a best-seller that has already reached bookshelves around the world and find new ways to both reinvigorate its content and aim for that elusive perfection. In my mission to create the perfect book, I could have asked for no better partner than expert and author Jawad Akhtar. His tireless effort, his attention to detail, and his commitment to a new edition of his first-ever book were second to none. While perfection may never truly be possible, I do believe we have come quite close! As always, your comments and suggestions are the most useful tools to help us make our books the best they can be. Let us know what you thought about this second edition of Production Planning and Control with SAP ERP! Please feel free to contact me and share any praise or criticism you may have. Thank you for purchasing a book from SAP PRESS! Meagan White Editor, SAP PRESS Rheinwerk Publishing Boston, MA meaganw@rheinwerk-publishing.com Acknowledgments PART I Production Planning Core Concepts 1 Introduction Goals of This Book Target Audience Structure and Content Organizational Structures in SAP ERP PART II 2.1 Breaking Down the Structure into Units Client Company Code Plant Storage Location Material Requirements Planning Controllers Capacity Planners Production Schedulers Production Planning in SAP ERP Characteristics of Production Types Processes in Production Planning and Control Product Costing SAP Calendar Public Holidays Holiday Calendar Factory Calendar Summary Configuration Specifics for Manufacturing Types 3 Configuration Basics of Discrete Manufacturing Material Master Bill of Materials Define Bill of Material Usages

3 3.2.2 Allowed Material Types in the Bill of Materials Header Bill of Material Status Bill of Material with History Requirement Item Category in Bill of Material Variable Size Item Formulas Bill of Material Explosion Types Bill of Material Selection (Order of Priority) Work Center Work Center Category Field Selection in the Work Center Standard Value Key Formulas for the Work Center Location Groups Control Key for Operations Routing Production Order Creation Maintain Order Types Number Ranges Order Type-Dependent Plant Parameters Planning Implementation Cost Accounting Production Scheduling Profile Default Values for the Generation of Operations Availability Check Define Checking Group Define Checking Rule Define Scope of Check Define the Checking Control Stock and Batch Determination Scheduling Scheduling Types for Production Orders Scheduling Parameters for Production Orders Scheduling Margin Key Reduction Strategy Confirmation Process Overview Parameters for Order Confirmation Single Entry Screen for Confirmation Time of Confirmation Reason for Variances Trigger Points Define Print Control Background Jobs Process Integration Summary Configuration Basics of Process Manufacturing Master Data in Process Industries Master Recipe Profile Task List Assignment to Material Types Task List Status Order Type-Dependent Parameters Master Data Planning Implementation Cost Accounting Production Scheduling Profile Process Management Control Recipe Destination Process Instruction Characteristic Process Instruction Category Process Message Characteristic Process Message Category Process Instruction Sheet Standard Settings and Tools Process Messages Create a Process Message Characteristic Process Message Destination Process Message Categories Process Instruction Category Process Instruction Types Using a Wizard or Process Instruction Assistant Creating a Self-Defined Process Instruction Category Creating a Self-Defined Process Instruction Characteristic Control Recipe/Process Instruction Sheets Create a Control Recipe Destination Scope of Generation Background Jobs Background Job for Sending Control Recipes

4 4.8.2 Background Job for Sending Process Messages Background Job for Deleting Process Messages Process Management Configuration: At a Glance Process Management: Configuration and Implementation Roadmap Process Manufacturing Cockpit Summary Configuration Basics of Repetitive Manufacturing Repetitive Manufacturing Profile Repetitive Manufacturing Production Type Reporting Points Automatic Goods Movements Reporting Points Confirmation and Kanban Activities Posting Separated Backflush Process Control Firming Planned Orders Automatic Stock Determination Batch Determination Procedure Reduction in Planned Order Quantities Reduction Period Create New Planned Orders on Goods Receipts Reversals Online Error Correction Reprocessing Errors Log Maintenance Movement Types for Stock Postings Naming the Repetitive Manufacturing Profile Summary of Repetitive Manufacturing Profile Settings Scheduling Planned Orders Display Entry Parameters for a Planning Table Maintain Rows Selection Material Staging Global Settings for Confirmation and the Logistics Information System Operational Methods Sheet Summary PART III Production Planning Workflow by Production Type 6 Production Planning for Discrete Manufacturing Process Overview Master Data Material Master Bill of Materials Work Center Routing Production Version Production Order Management Header Data Operations Overview Standard Trigger Points Components Overview Reread Master Data Statuses Scheduling Availability Checks Release Production Order Automatic Release Individual Release Collective Release Printing Material Withdrawal Goods Issuance against the Production Order Picking List Backflush Confirmation Confirmation at the Operations Level Progress Confirmation Confirmation for Order Confirmation Cancellation Display Confirmation Goods Receipt Goods Receipt: Manual Process Goods Receipt: Automatic Process Postprocessing Reprocessing Goods Movements Cost Calculation Settlement and Completion

5 6.11 Production Order Batch Traceability Using Work in Process Batches Configuration Settings Master Data Setup Business Processes for Work in Process Batches Work in Process Batches Reporting Additional Functions and Information Systems From Planned Order: Individual Conversion From Planned Orders: Collective Conversion Production Order Creation without Material Mass Processing Information Systems Summary Production Planning for Process Industries Process Manufacturing Overview Master Data in Process Manufacturing Material Master Bill of Materials Resource Production Version Master Recipe Creation Process Management Functions in Process Management Elements in Process Management Integrating Process Management with External Systems Process Management and Manufacturing Integration and Intelligence Process Instructions Process Instruction Sheet Process Order Execution Process Management in Action Creating and Releasing a Process Order Generating a Control Recipe Downloading and Sending a Control Recipe Maintaining Process Instruction Sheets Completing a Process Instruction Sheet Sending Process Messages Generating a New Control Recipe Execution Steps (XSteps) Repository for Standard XSteps Switching from Process Instructions to XSteps XSteps: General Information Parameters in XSteps Valuation in XSteps Control Recipe Destination in XSteps Process Instructions in XSteps Process Manufacturing Cockpit Process Messages Evaluation Miscellaneous Cross-Manufacturing Topics Summary Production Planning for Repetitive Manufacturing Overview Roles of Repetitive Manufacturing in Planning and Production Repetitive Manufacturing Process Flow Repetitive Manufacturing Master Data Material Master Bill of Materials Work Center (Production Line) Routing Production Version Material Requirements Planning in Repetitive Manufacturing Planned Independent Requirements Run Material Requirements Planning Planning Results Evaluate Planning Results (Material Level) Collective Availability Check Operational Method Sheet Planning Table in Repetitive Manufacturing Parameters Selection for the Planning Table Creating a Repetitive Manufacturing Planned Order in the Planning Table Capacity Planning Functions in the Planning Table Range of Coverage Material Staging Material Staging: Current Situation

6 PART IV Material Staging: Trigger Replenishment Material Document of Material Staging Production List Confirmation Overview Repetitive Manufacturing Assembly Confirmation Repetitive Manufacturing Component Confirmation Repetitive Manufacturing Activities Confirmation Repetitive Manufacturing Actual Assembly Confirmation Separated Backflush Postprocessing of Components Reversals and Scrap Document-Specific Reversal Document-Neutral Reversal Repetitive Manufacturing Actual Assembly Scrap Repetitive Manufacturing Actual Component Scrap Repetitive Manufacturing Actual Activity Scrap Reset Reporting Point Confirmation Collective Confirmation Costing Activities (Cost Object Controlling) Reporting Document Log Information Reporting Point Statistics Summary Production Planning Workflow Tools 9 Sales and Operations Planning Standard Sales and Operations Planning Overview Information Structures Planning Methods Planning Types in Standard Sales and Operations Planning Distribute Key Figures Working with Macros Flexible Planning Creating a Self-Defined Info Structure Planning Hierarchy Planning Type Working with Self-Defined Macros in Flexible Planning Row Attributes in a Planning Type Planning in the Planning Table Additional Features of Planning Tables Info Structure Entries in SAP Database Tables Maintaining Version Management Copy a Version Delete a Version Scheduling a Copy Version or Scheduling a Delete Version Forecasting Forecasting View in Material Master Forecast Profile Forecast Strategy Using the Forecast Profile Rough-Cut Planning Profile Create a Profile Pegged Requirements Events Create Events Assignment of Events Events in Planning Mass Processing in Sales and Operations Planning Planning Activity Setting Up a Mass Processing Job Scheduling the Mass Processing Job Standard Analysis in Flexible Planning Summary SAP Demand Management Planning Strategy Planning with Final Assembly Make-to-Order/Stock Production Requirements Class and Requirements Type Strategy Groups Maintain Requirements Class for Planned Independent Requirements Planned Independent Requirements Customer Independent Requirements

7 Creating Customer Independent Requirements Planning for Independent Requirements Stock/Requirements List for Independent Requirements Total Independent Requirements: Evaluation Total Independent Requirements: Reorganization Planned Independent Requirements: Reduction Summary Material Requirements Planning Process Overview Prerequisites Influencing Factors in Material Requirements Planning Lot Sizes Configuring Material Requirements Planning Lot Size Rounding Static Rounding Profile Scrap Assembly Scrap Component Scrap Operations and Component Scraps in Bill of Materials Scrap in Routing Safety Stock Safety Stock Availability Master Data Selection Material Requirements Planning Procedures Material Requirements Planning Types Configuring Material Requirements Planning Types Consumption-Based Planning Type VB: Manual Reorder Point Planning Type VM: Automatic Reorder Point Planning Type V1/V2: Manual or Automatic Reorder Point Planning with External Requirements Forecast-Based Consumption Planning Basics of Forecasting Type VV: Forecast-Based Planning Type R1: Time-Phased Planning Types of Planning Runs Single-Item, Single-Level Single-Item, Multi-Level Total Planning Online Total Planning Background Single-Item Planning, Sales Order Single-Item Planning, Project Scheduling Scheduling In-House Production Basic Date Determination Planned Order Dates Scheduling External Procurement Forward and Backward Scheduling Procurement Proposals Planned Orders Planned Order Profile Purchase Requisitions Executing Material Requirements Planning Planning File Entry and the Selection of Materials for Planning Net Requirements Calculation Logic Planning Control Parameters in Materials Requirements Planning Configuration Settings for Material Requirements Planning Material Requirements Planning Activation Scope of Planning Configuration Plant Parameters Configuration Material Requirements Planning Group Configuration Material Requirements Planning Run Analysis Stock Overview Stock/Requirements List Planning Calendar Material Requirements Planning Areas Configuring Material Requirements Planning Areas Set Up a Material Requirements Planning Area in the Material Master Running Material Requirements Planning at the Material Requirements Planning Areas Level Planning Results for Material Requirements Planning Areas Summary

8 12 Long-Term Planning Long-Term Planning Master Data and Planning Data Master Data: Bill of Materials Planning Data: Planning Quantity Planning Data: Version Number of Planned Independent Requirements Create a Planning Scenario Long-Term Planning: Business Process Create the Planning Scenario Enter Planned Independent Requirements for the Simulative Version Run Long-Term Planning (Simulative Material Requirements Planning) Evaluate the Long-Term Planning Stock/Requirements List Further Options in Long-Term Planning Manually Create a Simulative Planned Order Firm the Simulative Planned Order Using a Firming Date Calculate Average Plant Stock Copy Long-Term Planning Results to Operative Planning Evaluate Information Systems for Long-Term Planning Setting Up a Purchasing Information System for Long-Term Planning Evaluating with the Purchasing Information System for Long-Term Planning Setting Up an Inventory Controlling Information System for Long-Term Planning Evaluating the Inventory Controlling Information System for Long-Term Planning Capacity Planning Summary PART V Optimizing Production Planning 13 Special Procurement Types Overview Phantom Assembly Direct Production Direct Procurement Stock Transfer (Interplant Transfer) Withdrawal from Alternate Plant Production in Alternate Plant Subcontracting Consignment Pipeline Material Summary Capacity Requirements Planning Process Overview Capacity Requirements and Capacity Evaluation Capacity Requirements Standard Evaluation of Capacity Utilization Variable Evaluation of Capacity Utilization Cumulating the Capacity Requirements Checking Capacity Availability Finite Scheduling Dispatching Process Steps Profiles for Dispatching Dispatching Sequence Sequence-Dependent Setup Midpoint Scheduling Mass Processing Capacity Planning Table Dispatch Operations Deallocate Options in the Graphical Planning Table Summary

9 15 Classification Classification System Characteristics Create a Class and Assign Characteristics Assigning the Material Class to the Material Master Finding Objects in Classes Assigning an Equipment Class to Equipment Summary Co-Products and By-Products in Production Processes Check in Material Master Co-Product By-Product Bill of Materials Co-Product By-Product Process Order Co-Product By-Product Goods Issue Co-Product By-Product Confirmation Co-Product By-Product Goods Receipt Co-Product By-Product Documented Goods Movement Co-Product By-Product Cost Analysis Co-Product By-Product Summary Digital Signature PART VI 17.1 Configuration Steps to Set Up a Digital Signature Define Authorization Groups Define Individual Signatures Define a Signature Strategy Assign a Signature Strategy to a Document Management System Document Type Digital Signature in Action Digital Signature Logs Application of Digital Signature in SAP ERP Components Production Planning for Process Industries Quality Management Plant Maintenance Document Management System Engineering Change Management Summary Monitoring and Evaluation 18 Early Warning System Overview Exceptions Set Up Exceptions Define Requirements Follow-Up Processing Group Exceptions Set Up Periodic Analysis Schedule an Early Warning System Early Warning System in Action Exception Analysis Summary Reporting in SAP The Basics of Reporting Order Information System Selection Screen at the Header Level

10 Selection at the Operations and Components Levels with Options Selection Screen for Dates Multiple Selection Maintain Selection Maintain Variant Order Header in the Process Filter Settings Graphs Download Copy Selective Data to Microsoft Excel Print Automatic Goods Movement Capacities Production Resource/Tool Items Document Links Execution Steps Missing Parts Information System Standard Analysis Reports Discrete Manufacturing/Production Order Process Manufacturing/Process Order Repetitive Manufacturing Standard Analysis: Work Center Standard Analysis: Operations Standard Analysis: Material Key Figures Other Info Structures Standard Analysis: Goods Receipt in Repetitive Manufacturing Standard Analysis: Product Cost Data Browser QuickViewer SAP Query Maintain InfoSets Create User Groups Create Queries Assign a Transaction Code to a Query Summary Integration of Production Planning with Logistics Functions Integration Prerequisites Integration Aspects of Production Planning with Quality Management Configuration Steps Quality Management Master Data End-to-End Production Process Flow with Quality Management Integration Integration of Production Planning with Materials Management Managing Master Data Production Planning Master Data End-to-End Process Flow Display Automatically Generated Vendor Delivery Schedule Lines in the Scheduling Agreement Integration of Production Planning with Sales and Distribution (Make-to-Order Production) Managing Master Data Sales Order Creation Material Requirements Planning Run on Sales Order Line Item Conversion of a Planned Order to a Process Order Integration of Production Planning with Sales and Distribution (Assembly Processing) Integration of Production Planning with Project System (Engineer-to-Order Production) Managing Master Data Assigning a Material to the Project Material Requirements Planning Run on Material for Project-Based Production Conversion of a Planned Order to a Production Order Integration of Production Planning with Plant Maintenance Integration of Production Planning with SAP Manufacturing Execution Integration of Production Planning with SAP Manufacturing Integration and Intelligence Summary

11 Appendices A Comparison Table of Production Types B Glossary C The Author Index