Transcript ERP - Western Michigan University

Production Planning
Mixer
Snack Bar Line
Mixer
Form
Bake
Pack
Mixer
Production (200)
Mixer
Finished Goods Warehouse (300)
Raw Material Warehouse (100)
Work Centers for Fitter Snacker
Production Master Data
Company
Code
Valuation
Area
Plant
Work
Center
Material
Master
Routing
Capacity
Planning
Production
Orders
Bill of
Material
Product
Costing
Navigating Material Master Views
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Material Types
 A Material Type is used to classify materials:
 Defines material attributes like:
 Valuation (value of material as market changes)
 Procurement (internal, external or both)
 Controls screen sequence and number assignment
 Can restrict access using authorization groups
 A number of material types are pre-defined
 Abbreviations are abbreviations of German terms
 Users can create their own material types
 Usually best to copy a pre-defined type, then
modify
Material Types in Exercises
 ROH: Raw material
 Externally purchased only, no sales view
 Oats, Wheat Germ, Honey, Cinnamon, etc.
 HALB: Semifinished Product
 No purchase or sales view
 Dough for NRG-A and NRG-B bars
 FERT: Finished Product
 Produced internally, has sales views, no purchasing
views
 NRG-A and NRG-B bars
Other Material Types
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HAWA:
HIBE:
VERP:
LEER:
KMAT:
ERSA:
DIEN:
NLAG:
UNBW:
FHMI:
WETT:
PROD:
IBAU:
Trading Goods
Operating Supplies
Customer returnable packaging
Empty containers
Configurable material
Spare parts
Services
Non-stock, non-valuated material
Non-valuated, stocked material
Production resources/tools
Competitive products
Product group
Maintenance assembly
Documentation in Material Master
 The SAP R/3 system documents all changes
to the material master:
Click for documentation
Documentation in Material Master
Master Data – Bill of Material
 BOMs are represented as single-level
relationships between a material and its
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)
Routings
 Routings define the relationship between a
material and the sequence of workcenters
(operations) that are required to produce the
material
 Also specifies where sub-components and
sub-assemblies are needed in producing the
material
10
20
30
40
50
60
Functions of Production Orders
(part 1 of 2)
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Status Management: Tracking, User-defined status
Scheduling
Calculation of Capacity Requirements (detailed)
Costing/Collection of Costs
Availability Checks (material, capacity, PRTproduction resources and tools)
 Printing of Paper Orders/related documents
 Assembly drawings and instructions
 Inspection instructions
 Storage regulations
 Material Staging: withdrawal of materials used in
production, e.g. components and sub-assemblies
Functions of Production Orders
(part 2 of 2)
 Confirmations: quantities, activities, times
 Goods receipt: receipt of completed materials
 Period-end closing: Process cost allocation, overhead
costs, surcharges, WIP (work-in-process) calculation,
variance calculation, order settlement
 Archiving and retrieval
 Many more: rework, serial numbers, as-built, quality
control, etc.
 Production Orders capture actual data—
costs, dates, etc.
Status Management
(part 1 of 2)
 Status Management is one tool that can be used to
manage released production orders
 A status can allow, allow with warning, or block a
business transaction
 Two status types are available
 System status: internal, predefined, fixed number
 User status: freely definable, set by user
Status Management
(part 1 of 2)
Status
Status detail
Planned Orders vs. Production
Orders
 Planned Orders are for PLANNING
 Production Orders are for EXECUTION
Planned Order 3 weeks in future
Planned Orders 2 weeks in future
Planned Orders 1 week in future
Production Orders released today
Planning
Execution
Master Data for Production Orders
 Master Data is data that does not change frequently
 Master Data for the production order comes from:
 Material Master
 Bill of Material (BOM)
 Work Center
 Routing
 Production Resources/Tools (PRT)
 Materials like gages, fixtures, test equipment
 Can also be items like drill bits that can be
consumed in production but aren’t consumed
INTO the product
 Most Production Order data comes from BOM and
Routing
Archiving &
Deletion
Order Request
1
16
Order
settlement
Order Creation
2
Availability
Checks
15
Variance
Calculation
Goods Receipt
3
Production
Order
Cycle
14
13
WIP
Determination
4
Machine
Reservation
5
Order Release
6
12
7
11
Confirmation
Upload from
PDC system
10
8
Download to
PDC system
Print Order
9
Material staging
Material withdrawal
posting
Routing Selection
 Different routings can be selected for a product
depending on a number of criteria like:
 Raw material used
 Lot size
 Product features/configurations (variants)
 A complicated, automatic selection process
can be configured
Bill of Material (BOM)
 The system selects the FIRST Valid BOM it
finds
 Validity can depend on:
 Date (engineering changes)
 Customer
 Serial number
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