Supply Chain Management with Global Bike Company using SCM Section 1 - Prepping the Master Data in SAP ERP

Transcription

1 Supply Chain Management with Global Bike Company using SCM Section 1 - Prepping the Master Data in SAP ERP In this module the students make changes to the master data of the Global Bike Company (GBI) in SAP ERP. These changes are needed to facilitate planning in SAP SCM. Product SAP ERP Release 6.0 Global Bike International (GBI) Level Undergraduate Intermediate Focus MM/PP Version 3.03 V1.0 Authors Marius Talos Marc Savard Amar Ramudhin V2.0 Revisions Mark Springer V3.0 Revisions Mark Springer MOTIVATION This course is specifically designed for UA faculty members who want to introduce SAP Supply Chain Manager (SCM) in a supply chain management course. This section will be focusing on preparing data in SAP-ERP for an integration with SAP-SCM using the Global Bike International Company database. PREREQUISITES Required Knowledge o Basic knowledge of SAP ERP Master Data Recommended Knowledge o Basic understanding of the SAP ERP Planning process and related master Data NOTES Before starting you need to have an ERP client with the GBI database connected to an SCM system. Contact your hosting center to have the proper setup made.

2 Contents 2 0 OVERVIEW OF THE GLOBAL BIKE COMPANY Global Bike Supply Chain Global Bike International Company Dataset... 5 Company... 5 Locations... 5 Materials... 5 Bills of Materials... 6 Workcenters... 6 Storage locations Disrtribution Channels and Prices CREATE TRANSPORTATION ZONE CHANGE MASTER DATA TO PREPARE FOR SCM Distribution Centers... 8 Change of Node Type... 9 Change of Node Type Change material type Assign Transportation Zone to Customers ADD & CHANGE MASTER DATA TO PREPARE FOR SCM Create Production Version for materials in ERP Distribution Key Define Distribution Keys Create production version SCM Resources settings Change Work Centers... 33

3 3.4 Create Purchasing Information Records Display Info Records by vendor... 35

4 Course Objectives 4 After completing this course, you will be able to: Transfer master data from SAP ERP to SAP SCM, and create SAP SCM specific modeling data to complete the Supply Chain. Identify where to add master data to SAP SCM to have a fully functional Supply Chain Planning system. Develop a complete supply chain model in SAP SCM based on SAP ERP master data. Describe the modeling options that are available in SAP SCM and their effects on the SAP ERP system. Create a feasible production plan in SCM 0 Overview of the Global Bike Company In this section we will review the master data of Global Bike International Company. At the end of this exercise the participants should have a good understanding of the master data structure (vendors, plant, DCs, customers, work centers, BOMs) and the transactions used to retrieve the data. 0.1 Global Bike Supply Chain The Global Bike database was created by Stephen Tracy, Bret Wagner and Stefan Weidner. The database is widely used by University Alliance members. The Global Bike International Company produces 1 brand of bicycle and sells 25 trading goods. The company was set up with manufacturing facilities, distribution centers, vendors, and customer in both the USA and Germany. To simplify what is by nature a very data-intensive exercise, this series of labs deals only with the North American supply chain. Figure 1 shows the North American supply chain for Global Bike International after some changes to the master data. The supply chain includes one factory, two distribution centers, two vendors, and two customers. Figure 1 Global Bike International North American Supply Chain

5 0.2 Global Bike International Company Dataset The letter ## should be replaced in the course material by your team number. Where possible, the screenshots for data entry show ## in place of the dataset number. In display screens, this is of course not possible and the the dataset number will vary as the screenshots were compiled over several sessions. Company The company code of the Global Bike International Company is US##. The symbols ## represent your two-digit data set number. For example, if your data set number is 03, then your company code would be US##. Locations Each company has the following North American locations: One plant DL## (Dallas, TX) with three workcenters in each plant: o ASSY1000 work center o INSP1000 inspection o PACK1000 packaging Two vendors: o Boomtown Tire and Wheel (Cincinnati, OH) o Rapid Nuts and Bolts (Grand Rapids, MI) Two customers: o ## Beantown Bikes (Boston, MA) o ## Northwest Bikes (Seattle, WA) Two DCs: o SD## San Diego, CA o MI## Miami, FL The two customers noted above have recently moved to their current locations (and changed the company names in the process). You will make these changes in the data below. Materials The plant DL## produces many bikes, but we are concerned with two similar but distinct touring bikes. DXTR1000 Deluxe Touring Bike (Black) DXTR2000 Deluxe Touring Bike (Silver) One semi-finished product is currently used in the process to make the Deluxe Touring bikes: TRWA1000 Wheel Assembly These raw materials are currently bought from the vendors to make the Deluxe Touring bikes: TRTR1000 Tire TRTB1000 Tube TRWH1000 Wheel HXNT1000 Hex Nut LWSH1000 Lock BOLT1000 Bolt TRFR1000 Frame TRFR2000 Frame DGAM1000 Derailleur TRSK1000 Seat Kit TRHB1000 Handle Bar Kit 5

6 PEDL1000 Pedal Kit CHAN1000 Chain BRKT1000 Brake WDOC1000 Documentation PCKG1000 Packaging 6 There are other materials on the books at GBI, but they are trading goods (finished bikes purchased from other manufacturers) or parts used to make other bikes. Only the Deluxe Touring supply chain will concern us here. Bills of Materials The Deluxe Touring bikes are assembled from several purchased raw materials and semi-finished materials made by GBI. A BOM for the Deluxe Touring is given below. The only difference between the DTRX1000 and the DXTR2000 is the frame. Workcenters The workcenter ASSY1000 is an assembly workcenter that runs for eight hours a day at 85% efficiency. It is therefore available for production 6.8 hours a day, and has four separate assembly workstations for a total of 27.2 hours of available capacity per day. Storage locations Plant level For each type of material we have a separate storage location: RM## Raw materials SF## Semi finished products FG## Finished products

7 7 DC level For each DC center a storage location is defined for the finished product: 30 Finished products 0.3 Disrtribution Channels and Prices We have two distribution channels (Internet Sale and Wholesale). The price is defined for each distribution channel. The price of the products sold by the wholesale distribution channel is cheaper than the price of products sold over the internet. Material Description Internet Sale Wholesale DXTR1000 Deluxe Touring (Black) 390 USD 399 USD DXTR2000 Deluxe Touring (Silver) 450 USD 549 USD 1 Create Transportation Zone Each customer must have a specified transportation zone unique to that company when data are loaded into SAP SCM. You will create a single transportation zone for North America. To display transportation zone you have to go into the IMG in ERP system:. Menu path: SPRO - SAP Reference IMG Sales and Distribution Basic Functions Routes Route Determination Define Transportation Zone click on Click on New Entries.. In the top line, enter US for Ctry, ##1 for TranspZone, and ## Region NA for Description. Save your data and click on Back.

8 8 Scroll down to check your entry. Click on Back to exit. 2 Change Master Data to Prepare for SCM The master data changes and additions in this section are changes we must make specifically if we want to plan using SAP SCM. We could plan in SAP ERP without these changes. At the end of this section we will have all the master data required to have a meaningful model to transfer to SCM. 2.1 Distribution Centers In SAP ERP there is no difference between a plant and a distribution center. Technically a DC is just a plant where no manufacturing is performed. In order to separate the two functions for SAP SCM, manufacturing and distribution, we need to label some SAP ERP plants as distribution centers.

9 9 Change of Node Type To identify appropriate supply chain activities, we must reclassify some plants as distribution centers (customizing view). To do this we will change the node type of plant MI## and SD## from Plant to DC. These changes need to take place in the customizing view, or the IMG, where much of the organizational and rules configuration of the SAP client takes place. Change of Node Type First we must access the IMG menu. Enter the transaction SPRO in the transaction code field and hit Enter. Now click on SAP Reference IMG. In the resulting menu, explode the menu tree structure to find: Menu Path: Production Distribution Resource Planning Basic Settings Maintain assignment of node type plant and click.

10 10 [In the future, going into the IMG and executing a command will be shown as a single menu path: Menu Path: SPRO SAP Reference IMG Production Distribution Resource Planning Basic Settings Maintain assignment of node type plant and click. ] Double click on the Allocation of node type row.

11 11 Scroll until you locate location DL##, MI##, SD## In the node type, enter PL (Plant) for plant DL## and DC (Distribution Center) for SD##, MI##. Click Save. Click on Back to return to the main menu.

12 12 Click on Cancel. Click on Back until you are at the Easy Access Menu.

13 2.2 Change material type The planning will be done in SCM. For this reason, we have to change the MRP planning type for each of the materials in the dataset. Menu path: SAP Menu Logistics Materials Managements Material master Material Change Immediately or transaction MM02 Enter the product DXTR1000 and press Select view button. 13

14 Select the view MRP1 and click Enter. 14 Enter your plant DL## and press Enter. The actual MRP type is M1 (MPS, Auto Firm and Reschedule). To do the planning in SCM we need to change the type of our MRP procedure from M1 to X0 (without MRP, with BOM explosion).

15 15 In the field MRP Type enter X0. Save your setting. Repeat the procedure for the other finished good: DXTR2000. The changes for the other products: TRTR1000, TRTB1000, TRWH1000, HXNT1000, LWSH1000, BOLT1000, TRFR1000, TRFR2000, DGAM1000, TRSK1000, TRHB1000, PEDL1000, CHAN1000, BRKT1000, WDOC1000, PCKG1000, TRWA1000 are already done. 2.3 Assign Transportation Zone to Customers We must go back into the customer master data to change the Transportation Zones assigned to each customer. Menu path: SAP Menu Logistics Sales and Distribution Master Data Business Partner Customer Change Sales and Distribution or transaction VD02. In the initial screen enter: Customer 50## (Beantown Bikes) Sales Organization UE##. Distribution Channel WH Division - BI Click Enter.

16 Ensure that the Transportation Zone is set to ##1. Save your results. 16

17 17 Cancel to return to the main menu. Perform the same activity for the other customer. In the initial screen enter: Customer 120## (Northwest Bikes) Sales Organization UW##. Distribution Channel WH Division - BI Ensure that the Transportation Zone is set to ##1. Save your results. 3 Add & Change Master Data to Prepare for SCM 3.1 Create Production Version for materials in ERP A company will often have many different methods of manufacturing an item such as different component structures (BOMs), different operation steps (routings) or different manufacturing lines or work centers. A production version is a combination of a specific bill of material and routing. The production version defined in the ERP system is used to create a Production Process Model (PPM) or Production Data Structures (PDS) in SCM, which are the basic master data elements in SCM. At the end of this module, the participants will have created production versions for finished products DXTR1000, DXTR2000 and semi-finished product TRWA1000 in the US plant DL##. Distribution Key A distribution key specifies the split to be used to divide the quantities of a planned order or a production order into partial quantities. It establishes the relationship between time and the quantity produced. It includes a distribution function and a distribution type: The distribution function is the percentage of the quantity to be produced or consumed after a percentage of the production time has elapsed.

18 The distribution type defines whether the requirement is to be distributed discretely to the points defined for the function or linearly according to the definition in the distribution function. Define Distribution Keys In ERP system: Menu path: SPRO SAP Reference IMG- Production Basic Data - Bill of Material Item Data Item Data from Related Application Areas - Define Distribution Keys, click. Click on. 18 In the new entry screen enter: First row: Plant: DL## DKey: EQUA Description: Equal Distribution Key Function: S20 (Equal distribution) Type: 01 (Carry out distribution continuously through time). Click Save and after click Back until you reach the SAP Easy Access menu. If you are prompt for a customizing request just click on.

19 Create production version Menu Path: Logistics Materials Management Material Master Material Change Immediately or transaction MM02 Enter material DXTR1000 in the material field and click Select Views. 19 On the select view (s) popup window, select MRP4 and click Enter.

20 20 On the organizational level popup window, enter your plant number (DL##) and click Enter. On the MRP4 view, click the button Production Version.

21 Complete the Production Version box with the following values: Version: ##F1 Description: Production version for DXTR1000. Valid from - Today Valid to - One year from now Click the Details button. 21

22 In the new screen complete the Basic data with: From lot size: 1 To lot size : Alternative BOM: 1 BOM Usage: 1 Distribution Key: EQUA Detailed planning - Task List Type: Routing Place cursor in the Group field of the Detailed Planning row of Planning Data. Click on the search button of the Group field. 22

23 23 Go to the tab view Search using material form and click on Start search. In list select your material and click Copy.

24 A value was copied in the Group box and in the Group Counter box. Click on the Check button 24

25 If you get any warning close the popup window close the window of Production Version Details by clicking Cancel. 25

26 And then click. 26

27 27 Accept all the messages, if any, by clicking on Continue DXTR1000 (Finished product) was defined. Click on once more.. A production version for product

28 28 Click on Save. A confirmation message will be displayed. Repeat the process to create a production version for finished product DXTR2000 and semi-finished TRWA1000. Use the version names ##F2 and ##S1, with the specific description for each material. All other inputs remain the same. Be sure that you select the right routing number for your product. Click Back to the main menu when are you done. 3.2 SCM Resources settings Menu Path: Logistics Production Master Data Work Centers Work Center Change or transaction CR02 Enter: Plant DL## (USA) Work Center ASSY1000 Click Capacities button.

29 29 Enter 002 (Labor) for Capacity Category Enter SAP005 for Setup formula and SAP007 for Processing formula. Click on the Capacity header button.

30 Change the Capacity planner grp to 001. Enter Labor as the description of the capacity category. Change the Base unit of meas. To HR. Change the start time to 08:00:00 Change the Finish time to 17:00:00 Change the Length of breaks to 01:00:00 Change capacity utilization to 85 Change no of indiv. Cap. To 4 Check Relevance to finite scheduling and can be used by several operations and then click on APO Resource button. 30

31 Enter: Resource type Multimixed Resource Resource Category - Production Factory calendar US Active Version 01 (Normal available capacity) Click Planning Params tab. 31 Enter: Days Days+ 360 Check the box for Relevant to finite scheduling Click on Standard Capacity tab

32 Check the box External Capacity and press Adopt. 32

33 Save the changes. You may have to click on Save twice to exit to the main Change Work Center screen. 33 Repeat the process for the INSP1000 and PACK1000 workcenters. Use the same settings as for ASSY Change Work Centers We have to make some more changes to the work centers changes to be able to do planning in SCM. The capacity defined for each work center (and used for capacity requirements planning in SAP ERP) is not supported by the PDS (Product Data Structure), a master data element we will create and use for planning in SCM. For this reason we need to delete the capacity shift for each work center defined in our plants. To do this follows the path: Menu Path: SAP Menu Logistics Production Master Data Work Centers Work Center ## Change or transaction CR02. Enter plant DL## and the work center ASSY1000. Then click Scheduling button.

34 34 Delete the capacity SHIFT - Standard Day Shift, and then click Save button. Perform the same for workcenters INSP1000 and PACK1000. When are you done click Back until you reach SAP Menu screen.

35 3.4 Create Purchasing Information Records 35 To link the raw materials to the vendors, we have created Purchasing Info Records. The purchasing info record provides continuously updated information about the relationship between a specific material and a specific vendor. This data includes order unit, price, price changes, tolerances, reminder infos, historic data, statistics, texts, etc. SCM needs to receive this data from SAP ERP so it knows which vendors can supply which parts. 3.5 Display Info Records by vendor The required Purchasing Information Records have already been created. To display a list of purchasing info records by vendor follow the menu path: Menu path: Sap menu Logistics Materials Management Purchasing Master data Info Record List Display or transaction ME1L Enter your plant DL## and click Execute. Review the list of existing info records. When are you done click on the Back main menu. button to return to the

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