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Business Process Monitoring of Manufacturing Process
Business Process Monitoring of Manufacturing Process
So most of the time the manufacturing process starts with some automatic planning run
which creates Planned Orders for further processing. In our example we have a Material
Requirements Planning run on SAP ERP side. Of course you could also have some
corresponding planning runs in the Supply Network Planning or Production Planning in
SAP APO. All these planning runs are normally executed in background mode and hence
could be monitored by the job monitoring functionality from Business Process Monitoring.
For more information you could have a look into the Best Practice document “Best
Practice - Background Job Monitoring“.
Once the Planned Order is created it is either converted into a Purchase Requisition for
external procurement (out of focus in this blog) or into a Production Order (discrete
manufacturing) or Process Order (process manufacturing). The repetitive
manufacturing process is somewhat different and is also out of focus for this blog.
The conversion should take place at the so called Opening Date. If the conversion does
not take place on time the whole manufacturing process might be slowed down as the
involved machines need some respective setup time. With the creation of the
Production/Process Order some automatic steps are performed in background from the
production order processing, e.g. creating reservations or calculating planned order costs.
In a next step a Production/Process Order needs to be released which is actually the
starting point for production workers. The release should take place at a
scheduled Release Date. Similar to a delayed conversion also a delayed release might
slow down the whole manufacturing process.
When the goods are produced and the actual manufacturing itself is finished the
Production/Process Order gets confirmed. The confirmation is a separate document which
references one production order or an operation of a production order and the
corresponding status information contains e.g. the produced quantity as yield and scrap
as well as activities leading to actual costs. The order confirmation also triggers
several goods movement postings. On the one hand the finished product is updated
in the inventory via goods receipt posting. On the other hand the quantities of the
components used during the production are updated in the inventory via goods issue
postings, i.e. called back flushing. It often happens thatconfirmation errors occur
during these automatic goods issue postings which need to be corrected in a
timely manner (transaction COGI). Otherwise the real world differs from the inventory
information shown in the SAP system. During the order confirmation also FI/CO
documents are posted.
If a Production/Process Order shall be ended from a logistical viewpoint then you set it
to technical completed. Then the order can no longer be changed, capacity
requirements are deleted (entries in table KBED) and reservations are marked for deletion
so they are no more relevant for the MRP run.
Within such a manufacturing process there are of course many things that could be
monitored and Business Process Monitoring provides many technical and business
application specific monitors for this purpose which come out-of-the-box and
can be adjusted to the customer needs, e.g. by entering data for plants and
document types. Probably the four most important key figures are the
following:
• # of Planned Orders not converted:
Business Risk: If the planned orders are not converted on time the whole
production process will be delayed and products will not be produced on time
On the next level, "customizing" (i.e select-options in order to identify the "right"
documents) for the key figure has to be maintained, as well as threshold values which
will later on define the rating of the alerts.
Roughly spoken, this is all what needs to be done for setting up the monitoring. You can
then use the monitoring in the operative part of the monitoring session. As an entry point,
the system provides a general overview of the status of all alerts assigned to your
business process steps.
Navigating into the details of this process step, you will find a list with all recent alerts
thrown for this key figure. In this case, 181 Production Orders are overdue for release
since 5 days or longer. These overdue Production Orders can be viewed directly in the
monitored system using the Detail Infobutton.
After clicking the button in the SAP Solution Manager system, you will be asked to log on
to monitored backend system. Having done this, a list with all entries causing the alert
will be displayed. So all transactional data remains in the backend system and is not
transferred to the SAP Solution Manager.
If you like to see the details of a specific Production Order, just click on it and you will
be directly led to standard transaction CO03 (if your backend user has the appropriate
authorization) where you can process the issue further.
Next blog
The next issue of this blog will be available in the next weeks.