Transcript ERP - Western Michigan University

Module 11
Configuration
for
MRP
Semi-finished Materials
 Dough is a semi-finished material:
## NRG–A
(case)
NRG-A: Finished Snack Bars
## Dough NRG–A
(lb)
## Oats
(lb)
## Wheat Germ
(lb)
## Cloves
(lb)
## Cinnamon
(lb)
## Canola
(gal)
## Nutmeg
(lb)
## Honey
(gal)
## Carob Chips
(lb)
Dough NRG-A: Semi-finished
Raw Materials
## Raisins
(lb)
## Vit/Min Powder
(lb)
Semi-finished Materials
 Finished Materials: ## NRG-A and ## NRG-B
 Snack bars, which are manufactured in-house and
sold
 Semi-finished Materials: ## DoughNRG-A and ##
Dough NRG-B
 Dough, which is mixed from raw materials and used
to make snack bars
 Neither purchased nor sold
 Raw materials: ## Oats, ## Wheat Germ, etc.
 Materials which are purchased and used to make
the semi-finished dough
Production Master Data
Work
Center
Routing
Capacity
Planning
Orders
Material
Master
Bill of
Material
All four types of production
master data are required to
execute production planning
and scheduling
Product
Costing
Capacity planning
and product costing
are not considered
in this course
Bill of Material (BOM)
 BOMs are represented as single-level
relationships between a material and it’s
components and sub-assemblies
## NRG–A
(case)
BOM for NRG-A
## Dough NRG–A
(lb)
## Oats
(lb)
## Wheat Germ
(lb)
## Cloves
(lb)
## Cinnamon
(lb)
## Canola
(gal)
BOM for
Dough NRG-A
## Nutmeg
(lb)
## Honey
(gal)
## Carob Chips
(lb)
## Raisins
(lb)
## Vit/Min Powder
(lb)
Bill of Material (BOM)
 BOMs are represented as single-level relationships
between a “parent material” and it’s components and
sub-assemblies, known as “children”.
BOM for ## NRG-A
## NRG–A
(7 cases)
## Dough NRG–A
(500 lbs)
Parent
Child
 In SAP, the BOM is referred to by the parent
component.
 Complicated BOMs are built up level-by-level
Bill of Material (BOM)
 Both the quantity and unit of measure for the parent
component and the quantity and unit of measure for
the child component must be entered when creating
the BOM
BOM for ## NRG-A
## NRG–A
(7 cases)
Quantity and
Unit of Measure
## Dough NRG–A
(500 lbs)
Quantity and
Unit of Measure
 Combined with the ability to define alternate units of
measure, this method of defining the BOM provides a
high degree of flexibility
Bill of Material (BOM)
 The quantity and
unit of measure
for the parent
component are
entered in the
header of the
BOM as the base
quantity—7 cases
in this example.
Bill of Material (BOM)
 The quantity and unit of measure for child components
are entered in the item overview of the BOM—500 lb.
of dough in this example.
Bill of Material (BOM)
 In the BOM for Dough, there are a number of child
components:
Work Centers and Storage Locations
for Fitter Snacker
 Raw Materials are stored in storage location
100
 Semi-finished materials are produced on the
Mixers workcenter and stored in storage
location 200
 Finished materials are produced on the
Bakeline workcenter and stored in storage
location 300
Mixer
Snack Bar Line
Mixer
Form
Bake
Pack
Mixer
Production (200)
Mixer
Finished Goods Warehouse (300)
Raw Material Warehouse (100)
Work Centers and Storage Locations
for Fitter Snacker
Workcenters
 Production is carried out at workcenters.
 In the SAP R/3 system, workcenters could
represent machines or groups of machines,
production lines, assembly lines, employees or
groups of employees.
 Workcenters have capacities defined and
assigned that can be used for planning to
make sure the there is sufficient capacity
available for the production orders that are
released.
Routings
 Routings specify the workcenters a material
must be routed through to be produced
 It also specifies the capacity needed to
process a production order:
Capacity Required
Workcenter Visited
Capacity
 Workcenters define the available capacity in
the production facility
 Routings define the capacity required by a
particular production order
 Capacity planning involves scheduling
production orders so that the capacity required
by production orders does not exceed the
capacity available at workcenters
Material Assignment
 The routing also determines at which
operations material that is needed in
production can be issued.
 The material required is determined from the
BOM.
 The routing defines when it can be used.
Material
Material
Material
Material Assignment
Assigned via BOM:
All materials assigned to
first operation
OP
OP
OP
OP
OP
……..
0010 0020 0030
0080 0090
Assigned via Routing:
Materials can be assigned
to specific operations
Material
Material
OP
OP
OP
OP
OP
……..
0010 0020 0030
0080 0090
Material
Material Assignment
Materials a selected in the Material Component Overview Screen,
then assigned to an operation number in the routing.
Operations are numbered 10, 20, 30, etc. by SAP to allow new
operations to be inserted in a routing without having to renumber
all operations.