Ste by Step Sap PP User Manual PDF

Organization Sujan Barre Thomas Anti-Vibration Systems Pvt. Ltd.
, Thane
Project VISION
Document END USER MANUAL Version 1
Module Production Planning (PP) No.
END USER MANUAL
SAP, PRODUCTION PLANNING (PP) MODULE
PROJECT
VISION
SUJAN BARRE THOMAS ANTIVIBRATION SYSTEMS PVT. LTD.,
Thane
Prepared By,
HARRIS PANCHAL
SAP Consultant, PP
Mahindra IT Consulting Pvt. Ltd., Mumbai
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Organization Sujan Barre Thomas Anti-Vibration Systems Pvt. Ltd., Thane
Project VISION
DOCUMENT CONTROL
Date of Date of
Sr. No. Revision Remarks
Creation Modification
1 1.0 07-February-09 07-February-09 ---
Security Classification: COMPANY CONFIDENTIAL
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Contents
1. CHECK SCHEDULING AGREEMENT MD04....................................................................................4

2. CHECK STOCK OF MATERIAL - MMBE.............................................................................................6
3. EXPLODED BOM VIEW CS11 ..........................................................................................................9
4. RESERVATION CREATION ...............................................................................................................11
4.1a BY MANUAL CREATION THROUGH MB21...................................................................11
4.1b RESERVATION DISPLAY PRINT FOR INTIMATION MB25 .......................................14
4.1c STOCK TRANSFER POSTING MB26 ............................................................................18
4.2 BY MANUAL CREATION THROUGH MB1B ....................................................................19
5. CHECK BILL OF MATERIAL CS03 ................................................................................................21
5.1 CHECKING STANDARD BOM.............................................................................................21
5.2 ADDING AN ALTERNATIVE BOM .......................................................................................23
6. CHECK ROUTING CA03 .................................................................................................................25
6.1 CHECKING STANDARD ROUTING ....................................................................................25
6.2 ADDING AN ALTERNATIVE ROUTING ..............................................................................28
7. PRODUCTION ORDER CREATION MANUAL CO01..................................................................30
8. SHOP FLOOR PRINTING PRODUCTION ORDER CO04 ...........................................................35
9. PRODUCTION ORDER CONFIRMATION CO11n ..........................................................................39
10. QUALITY INSPECTION QA32.......................................................................................................43
11. PRODUCTION ORDER SETTLEMENT KO88 ..............................................................................51
12. PRODUCTION ORDER TECO (Technically Complete) CO02 ................................................53
13. CHECK PRODUCTION ORDER REPORTS ....................................................................................55
13.1 PRODUCTION ORDER INFORMATION SYSTEM - COOIS ............................................56
13.2 CAPACITY PLANNING - STANDARD OVERVIEW CM01 ............................................61
13.3 CAPACITY PLANNING - CAPACITY EVALUATION CM50 ..........................................63
13.4 ORDER PROGRESS REPORT CO46 ............................................................................66
13.5 DISPLAYING PRODUCTION ORDER CONFIRMATION CO14 ....................................68
13.6 CHECK PRODUCTION ORDER DELIVERY MB51........................................................69
13.7 CHECK RAW MATERIAL ISSUE MB51 .........................................................................71
13.8 CHECK RAW MATERIAL RECEIPT MB51.....................................................................73
13.9 MATERIAL USAGE ANALYSIS - MCRE............................................................................75
13.10 ANALYZE PRODUCTION ORDER KKBC_ORD ..........................................................77
13.11 CHECKING FAILED GOODS MOVEMENT - COGI ........................................................79
14. PRODUCTION ORDER THROUGH DEMAND MANAGEMENT ..................................................80
14.1 CREATE PLANNED INDEPENDENT REQUIREMENT MD61.......................................80
14.2 MRP AT PLANT LEVEL MD01.....................................................................................83
14.3 MRP AT MATERIAL LEVEL MD02 ..............................................................................85
14.4 PRODUCTION ORDER CONFN. WITH REWORK CO11n............................................93
14.5 PRODUCTION ORDER CREATION REWORK CO07 ................................................97
14.6 REWORK PRODUCTION ORDER CONFIRMATION CO11n ......................................101
14.7 GOODS RECEIPT OF REWORK ORDER MB31 .........................................................104
15. MRP FOR PLANNED ORDER + PURCHASE REQUISITION....................................................107
16. CO-PRODUCT SCENARIO ............................................................................................................114
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1. CHECK SCHEDULING AGREEMENT MD04
Sales & Distribution (SD) Module would be inputting Scheduling Agreement in the SD Module which
would be visible in the Stock Requirement List (Dynamic Listing).
SAP ECC menu Logistics Production MRP Planning Evaluations

Stock/Requirements List
Transaction code MD04
Here enter the Material and the Plant whos Requirements are to be checked.
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Here you can see the Scheduling Agreement inputted by SD.
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2. CHECK STOCK OF MATERIAL - MMBE
The Stock of the Raw Material is checked against the Selection criteria.
SAP ECC menu Logistics Material Management Inventory

Management Environment Stock Stock Overview
Transaction code MMBE
Double click on the Transaction code and give the selection condition as per your requirement.
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Click on Execute
The System will Show you the Stock as of that particular Item. The system will show you the Actual
stock lying at different areas such as Unrestricted, Quality Inspection, Reserved and Blocked Stock etc.
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If the stock is not available at IS01 (Issuing In-Between Storage Location), then, In-House Stock
transfer of components has to be done, i.e. ST01 to IS01. Production Order will be consuming the
Stock from ST01 (General Storage Location) to IS01 (In-between / WIP Storage Location).
Also if the production department has determined the total quantity required for a particular material,
say ROH, then they can check the same by exploding the total BOM Quantity.
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3. EXPLODED BOM VIEW CS11
To check the Total Raw Material requirement by means of Exploding the Total BOM of a particular
Material.
SAP ECC menu Logistics Production Master Data Bills of Material

Reporting BOM Explosion Material BOM
Transaction code CS11
Enter Material / Plant / Required Qty. / BOM Application and click on Execute icon.
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After the execution, it will show the Total Requirement for that Finish Product in terms of Raw Material
requirement.
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4. RESERVATION CREATION
4.1a BY MANUAL CREATION THROUGH MB21
Now known the total quantity the Reservation needs to be created for the total requirement which was
being put at the time of exploding the BOM.

Management Reservation Create
Transaction code MB21
Enter Movement No.: 311 for Plant 1000.
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Enter Material, its Quantity, Unit oF Measure, the Receving Storage Location (IS01) and Storage
Location (ST01)
And Click on SAVE. Reservation is created and it will be shown with a Green Tick and a Reservation
No. being created.
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Note the Reservation No. shown in the System Status bar.
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4.1b RESERVATION DISPLAY PRINT FOR INTIMATION MB25

Management Reservation Reservation List
Enter Material & Plant 1000.
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Click on Execute
Reservation List Display will be seen.

Select the Reservation Line and Click on Change Layout From Drop Down menu
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Select Choose to select the saved Layout.
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Now you can see the details as per the selected Layout.
Select this line and Click on Print Option. Once the Spool is created, go to Spool Management to select
the print to be printed as a Hard Copy which then can be given to the Stores for issuing the material
from ST01 to IS01.
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4.1c STOCK TRANSFER POSTING MB26

Management Reservation Picking
You can enter here the Material / Reservation No. / Order No. / Plant as per your filtering requirement.
After entering you can simply select the One Reservation which you want to post, multiple selection is
also possible. If only 1 is to be posted then you need to delete the other postings and then Post the one
which was kept.
Goods movement would take place, which would mention it by Displaying a Green Tick mark in the
status bar.
Now the required material is available at IS01.
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4.2 BY MANUAL CREATION THROUGH MB1B
SAP ECC menu Logistics Logistics Execution Internal Whse

Processes Posting Change Inventory
Management Enter Posting Change
Transaction code MB1B
Here with this TCode you can directly post the required stock within plant.
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Enter the following details on the main Screen viz.

1. Movement Type: 311
2. Plant: 1000
3. Storage Location (Where the goods exists, Transfer from location): ST01
On the next screen Enter the following:

1. Rcvg SLoc (Where the material is needed to consume): IS01
2. Enter the Material details and Storage Location
And SAVE to post the material to the required Storage location.
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5. CHECK BILL OF MATERIAL CS03
5.1 CHECKING STANDARD BOM
SAP ECC menu Logistics Production Master Data Bills OF Material

Material BOM Display
Now enter the Material number of which you BOM you want to see and execute.
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System will show you the Bill Of Material with details like material included in bill of material, description
of the component, quantity required with unit of measure.
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5.2 ADDING AN ALTERNATIVE BOM
SAP ECC menu Logistics Production Master Data Bills OF Material

Material BOM Create
At times there are chances that an Alternative Material is available to produce a particular component.
In that case an Alternative BOM for the same FERT would be required.
To do so, CS01 can be used to create an Alternate over an Existing BOM.
It would highlight that an Alternative 2 added to BOM and a New Page for entering the BOM
components would come where you can enter the new / alternate components.
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Other relevant details such as Storage Location and SAVE the BOM.
Once you have created it and when you open the BOM in change mode it would show you 2
alternatives and you can select which one you want to view / modify.
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6. CHECK ROUTING CA03
6.1 CHECKING STANDARD ROUTING
SAP ECC menu Logistics Production Master Data Routings

Standard Routings Display
Transaction code CA03
Enter the Material Number & Plant to display the Routing.
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System will display the routing of the material with details such as work center used operation
performed, Base quantity and the Activities. If the Group No. is already visible in the field, remove the
same and give Enter.
A Production Resource Tool (PRT) i.e. in case of SBT it is a Mould can be checked. In the above view
th
9 Column shows the TICK MARK which is grayed for PRT being applied to that operation. Select this
operation and click on above.
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CONTROL KEY:
You maintain the control key for operations in Customizing for Shop Floor Control. This is customizing
operation.
For SBT Scenario we are using 3 Control Keys viz.

1. PP01 - Routing/Ref. op. set - internal proc.
2. PP03 - Routing - in-house prod. auto. goods rct
3. PP07 - For Rework
PP01
Is used for all Operations other than the Last Operation as it has a Auto GR Tick which will allow the
components to be Goods received after the Final confirmation.
PP03
Is used for the Last operation or where Goods Receipt is to take place.
NOTE: Auto Goods Receipt can take place in 1 Operation only in the whole Routing sequence.
PP07
This is specifically used for to be used in Rework Order operations. Manual GR is mandatory for
Rework Orders.
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6.2 ADDING AN ALTERNATIVE ROUTING
To add an alternative routing you have through TCode CA01 itself.
SAP ECC menu Logistics Production Master Data Routings

Standard Routings Create
Transaction code CA01
Here it would show that Sequence No. 1 with Group Counter 1 is the only one existing. Hence to create
an Alternate Routing for the same FERT, i.e. if 1 Single Product is having more than 1 way of
manufacturing the product.
Click on NEW .
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Here you can see the Counter as 2.

Enter the Usage as 1 and Status 4 and click on Operations.
Now you can enter the new sequence of operation that you want and give Enter.
Enter the Setup Time, Machine Time and Labour Time and SAVE.
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7. PRODUCTION ORDER CREATION MANUAL CO01
SAP ECC menu Logistics Production Shop Floor Control Order

Create With Material
Transaction code CO01
Enter the following:

1. Material Number: XXXXXXXX
2. Production Plant: 1000
3. Order Type ZS01
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1. Quantity of Production
2. Basic Dates (As per the Scheduling Type)
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As we have an Alternative Routing for the FERT, you need to select the Icon Production Version
in the top frame.

It would then prompt you for the Routing which needs to be selected for the FERT as per the machine
availability.
Select the required sequence and then you can continue as per the regular Production Order
execution.
PRE-REQUISITE FOR PRODUCTION VERSION:

Production version needs to be maintained in Work Scheduling View or MRP4 View of the
Material Master for the FERTs who have more than 1 combination of BOM and/or Routings.
Now, Click on the following:

1. Material Availability Check
It would show that the Material is available or not, if not it would mention that the material is shortage
and material need to be made available at the required storage location.
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Click on the following:

1. Capacity Check
It would show whether the Capacity is Available or not.
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Click on the Calculator on the Top Frame, to calculate the costs. Thereafter the system should
message as shown below.
Click on the Green Flag to RELEASE the Order.
System would show that the Order has been released.

Now you can SAVE the production order and note the Production Order No.
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8. SHOP FLOOR PRINTING PRODUCTION ORDER CO04
SAP ECC menu Logistics Production Shop Floor Control Control

Print
Transaction code CO04N
Enter the Production Order No. & Plant and give Execute.
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Select the Order description line and Press F8 (Execute).
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Select OWN SPOOL REQUESTS from the Pull Down Menu and select the latest Spool and select the
printer to Print the Shop Floor Paper.
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The Production Order print can now be taken by the Production Supervisor and can move the same
along with the Material being provided from IS01.
Once the Production Order is printed the same cannot be printed as a New Print, it has to be printer as
a RE-PRINT and the Heading would show DUPLICATE for the Shop Floor personnels to understand
that it is a Duplicate Print of the prodcution Order.
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9. PRODUCTION ORDER CONFIRMATION CO11n
SAP ECC menu Logistics Production Shop Floor Control

Confirmation Enter For Operation
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As we would be Confirming the Order Operation Wise we can go for Time-Ticket Confirmation.
Enter the Order No. and the Operation which you want to confirm and Click on ACTUAL. DATA
to get the Existing Data which has come along with the Production Order. Here you
can now enter the ACTUAL Data which you have got through Production to be seen as the Variance
during the Production Order reporting.
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Also select on Confirmation Type, for the Qty is to be processed and the reservations to be cleared,
select Final Confirmation and Clear Open Reservations.
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Also you can click on Goods Movement to enter the Actual material usage for
the Qty entered on the main confirmation screen.
Here you can see 2 Goods Movement i.e. Goods Issue and Goods Receipt to be happening in a Single
Confirmation command.
Thereafter click on SAVE.
Check for any System Messages which appear in the Status Bar.
Now the material has been posted to QA for Quality Inspection. The same can be checked in the Stock
Overview List of the FERT material.
Material qty. can be seen in Quality Inspection Stage.
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10. QUALITY INSPECTION QA32
SAP ECC menu Logistics Quality Management Quality Inspection

Worklist Inspection Change Data
Transaction code QA32
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First check the Stock Overview MD04 for the FERT material.
You can check the QM Lot being created.
The inspection of the components would be done in the QA Department and thereafter you can type in
the TCode QA32 for viewing the Inspection Lot which has been created in the QA.
In the Inspection Lot Enter Plant & Material whos Inspection Lot is to be checked.
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Select the Inspection Lot which is to be confirmed after Inspection and click on Usage Decision Box at
the top .
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Select the Usage Code 04 GOODS RECEIPT FROM PRODUCTION ACCEPT and Give ENTER
and select on INSPECTION LOT STOCK .
Here you can enter the Quantity which is OK, To Be Scrapped or to be moved to Block Storage.
For E.g.:
Total Qty.: 5 Nos.
Unrestricted Use: 3 Nos.
To Block Storage (Rework): 1 Nos.
To New Material (Scrap): 1 Nos.
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As the Scrap would be posted against a Pre-Defined Scrap material, say TEST-SCRAP, the Material
has to be selected against To New Material.
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After the Usage Decision is Saved, selected Inspection Lot appears with a TICK mark on its left side
and a Lot No. is created which can be seen at the System Status bar.
Click on REFRESH button to see the QM Lot being cleared (not appearing anymore in the list).
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You can also check the Stock Overview for this FERT component whose inspection has been done.
The same can be done through Transaction Code MMBE.
Also you can see that the Qty has been reduced from Quality Inspection Stock and Qty. 3 nos. has
been moved to Un-Restricted Use and 1 Nos. in Blocked Storage.
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11. PRODUCTION ORDER SETTLEMENT KO88
SAP ECC menu Logistics Production->Shop Floor Control->Period End

Closing ->Settlement-> Individual Processing
Transaction code KO88
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On the: Initial Screen, make the following entries:

Field name User action and values Comment
Order 1000128 Example
Settlement period 10 Example
Fiscal year 2008 Example
Processing type Automatic Example
Deselect Test run & Select Check trans. Data. Click on Execute Button
Variance amount has been settled to the Price Difference account
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12. PRODUCTION ORDER TECO (Technically Complete) CO02
The production Order remains Open and Changeable until it is explicitly completed. In this context,
distinction is made between logistical and the accounting based completion.
TECO After the completion of the production order the order is no longer logistically relevant; that is, it
is marked as being no longer MRP relevant, and all the reservations for the components and capacity
requirements that may still exist are deleted. The production order is assigned the status TCMP, which
stands for Technically Completed (TECO). It is also now no longer possible to post any sots to the
production order. Moreover, it is no longer possible to trigger any confirmation for the production order.

Change
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After opening the order in Change Mode, from the pull down menu select, Functions->Restrict
Processing -> Technically Complete.
You can see now that the Order Status has now changed to TECO.
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13. CHECK PRODUCTION ORDER REPORTS
SAP ECC menu Information systems General Report Selection

Production Planning Production Control
All the necessary reports for PRODUCTION PLANNING Module can be get from the above menu.
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13.1 PRODUCTION ORDER INFORMATION SYSTEM - COOIS
The order information system is a tool for shop floor control and process industries with reporting
functions for production orders, planned orders and process orders. Evaluations take place - as with the
IOC logical database, via the original order tables.
SAP ECC menu Information systems General Report Selection

Production Planning Production Control Order
Information System
Transaction code COOIS
On the Production Order Information System screen, make the necessary entries to run the report as
desired.
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You can view all the orders in the system, including the orders with deletion flags or deletion indicators.
Archived orders are not taken into account.
The order information system has the following display options:

In an individual object list, a list is generated for the selected object (for instance, order header,
operation, and component). You can define the structure and appearance of the individual
object list with a layout
On the object overview the individual orders are displayed with their subordinate objects in a
hierarchical structure. With an overall profile, you can define which fields are displayed and
which objects (order headers, items, sequences, and so on) are read or displayed. In addition,
you can define which fields are displayed for the individual objects
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Reports regarding SCRAP / REJECTION can also be seen through this report where in you need to
select CONFIRMATION as the header of the report.
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HEADER - ORDER WISE
HEADER - ITEMWISE
HEADER - DOCUMENTED GOODS MOVEMENT
HEADER - OPERATION WISE
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HEADER - COMPONENT WISE
HEADER - CONFIRMATION WISE
HEADER - AUTOMATIC GOODS MOVEMENT WISE
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13.2 CAPACITY PLANNING - STANDARD OVERVIEW CM01
You can use capacity evaluations to analyze capacity loads in your company. You can adjust the
analyses for each user according to the planning level, planning horizon and the area of responsibility.
Available capacities and capacity requirements can be selected according to various criteria and
cumulated using any period split you choose.
You can use work center hierarchies to cumulate the available capacities of production work centers
and their capacity requirements to superior planning work centers.
SAP ECC menu Logistics Production Capacity Planning Evaluation

Work Center View Load
Transaction code CM01
On the Capacity Planning: Selection screen, make the necessary entries to run the report as desired.
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In the capacity evaluation you can display the planned capacity requirements and the remaining
capacity requirements
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13.3 CAPACITY PLANNING - CAPACITY EVALUATION CM50
To Check all the Capacity Available for more than 1 Work Center.
SAP ECC menu Logistics Production Shop Floor Control Information

System Capacity Evaluation Extended Evaluation
Work Center View
Transaction code CM50
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On the Capacity Evaluation : Selection screen, make the necessary entries to run the report as desired.
Here you can get a complete capacity evaluation for more than 1 Work Center, i.e. a Range of Work
Centers can be inputted here.
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Likewise, all the selected range of work centers can be seen here.
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13.4 ORDER PROGRESS REPORT CO46
When you work with the order progress report, you can
Choose the individual objects in the report in a flexible manner

Adapt the contents and the presentation of the report (for example, include hierarchy levels
later)
Execute functions (for example, convert planned orders)
Go to object maintenance (for instance, Change production order)
SAP ECC menu Logistics Production MRP Evaluations Order

Progress
A progress report can be displayed for more than one sales order or a WBS element. The requirement
elements and procurement elements are displayed.
If you want to display all objects for a sales order, enter the sales order with item number. By entering a
material or production order, you can further limit the number of objects displayed.
If you want to display objects from the Project System, you have to choose a network or a material. The
selected object (network or material) must be assigned to a WBS element. Depending on what you
have entered, a structure is displayed, from which you can select a network or material.
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13.5 DISPLAYING PRODUCTION ORDER CONFIRMATION CO14
You use this to display the confirmations of production orders.

Confirmation Display
On the Display Production Order Confirmation: Initial screen, make the necessary entries to run the
report as desired.
If several confirmations exist, the system branches to an operation overview containing the
confirmations. Choose one or more confirmations. If you choose more than one confirmation then you
can switch between confirmations in the detail display. You can print the operation overview and define
a user-specific layout for it (column selection and sorting).
If only one confirmation exists, the system branches directly to the detail screen for the confirmation.
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13.6 CHECK PRODUCTION ORDER DELIVERY MB51

Management Environment List Displays Material
Documents
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After selecting MB51 Enter filtering criterias such as Material, Plant, Movement Type, etc.
Click on Execute.
st
2 highlighted in the Boxes displays the GR done 1 by Original Production Order and later through
Rework Production Order.
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13.7 CHECK RAW MATERIAL ISSUE MB51

Documents
Enter and Input the Filtering criterias. Here we input 261 and 262 Goods Movement for Issuing of Raw
material.
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13.8 CHECK RAW MATERIAL RECEIPT MB51

Documents
Enter and Input the Filtering criterias. Here we input 101 and 102 Goods Movement for Issuing of Raw
material.
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This report would display the Total Receipt of Raw Material in the plant i.e. the Qty. which is being
procurred externally.
Note: Attached herewith is an Non-SBT example (as no live data is available at present in the System).
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13.9 MATERIAL USAGE ANALYSIS - MCRE
SAP ECC menu Information Systems Logistics Production

Material Material Consumption
Transaction code MCRE
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Enter the Plant and Production Order whose Material Consumption Analysis is to be done and click on
Execute.
Click on Sujan Barre Thomas and click on Switch Drill Down and select the Level at which you want to
analyze. Say you want to analyze at the Order Level, so select Order.
Here you can see the Total Requirement Qty (Planned Qty.) vs Withdrawal Qty. (Actual Consumption).
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13.10 ANALYZE PRODUCTION ORDER KKBC_ORD
Transaction code KKBC_ORD
This will report based on Production as well as Accounting for a particular order.
Enter the Order No. which is to be analyzed.
You can also select Layouts to select which type of Report you would like to see for that particular
order.
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Say you select the first layout, Target/Actual Comparison, now click on Execute.
Select on to select the required fields.
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13.11 CHECKING FAILED GOODS MOVEMENT - COGI
SAP ECC menu Logistics Production-Process Process Order

Environment Material Movement Failed Goods
Movement
Transaction code COGI
You can check Errors in Goods Movement through COGI Transaction code.
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14. PRODUCTION ORDER THROUGH DEMAND MANAGEMENT
14.1 CREATE PLANNED INDEPENDENT REQUIREMENT MD61
As part of material requirements planning using the net change method, the planned independent
requirements are exploded across the entire BOM structure. As a result, the system also determines
dependent requirements for purchased parts and raw materials.
SAP ECC menu Logistics Production Production Planning Demand

Management Planned Independent Requirement
Create
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On the Create Planned Independent Requirement: Initial Screen, enter the

following data:
Field name Description Comment

Planned Independent Requirements for
Material Enter Material Code. Finished Good MTS
(You have to select the
radio button)
Plant Enter Plant Code. Always Enter Production
Plant.
Selection parameters
Select Verson Always select Active
Version
Number. Version
Planning horizon
From From Date Change system default
if necessary.
To To Date
The default planning
period is M (month).
Select the appropriate You can change the
Planning period
Planning Period default value for this
field by changing the
user settings.
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Check the Stock Requirement List for the same through MD04.
The Independent Requirement which is generated can be seen here in the RED box being highlighted.
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14.2 MRP AT PLANT LEVEL MD01
MD01 is used for running the MRP for specific plant or number of plants to maintain the scope of
planning. In the scope of planning you can maintain number of plants and can use the scope to run
MRP for maintained plants.
Usually this is followed when the First MRP is run at the time of first Run in Production Environment.
Thereafter MRP is run at Material Level i.e. MD02. So if you want to run MRP for all plant and material
in that case we use MD01
SAP ECC menu Logistics Production MRP Planning Total

Planning Online
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14.3 MRP AT MATERIAL LEVEL MD02
MD02 is used to run MRP for a particular Material. This run would be for just one material , single item ,
multi level ( will explode whole BOM for particular material )

Planning Single Item, Multi Level
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Enter the following details:

1. Enter Material Name
2. Enter Plant
3. Select Processing Key
Specifies the type of MRP run. The following types are possible:
net change planning: NETCH
net change planning in the planning horizon : NETPL
online regenerative planning : NEUPL
4. Create Planned Order / Purchase Requisitions (In case of BOP)
5. Delivery Schedules: Whether To Create or No
6. Create MRP List
7. Planning Mode & Scheduling
Above details are shown in the image above. ENTER to run the MRP.
An MRP List will be generated.
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Now the Planned Orders will be generated for this PIR.

Through MD04 you can select this Planned Order. Shown below.
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Select the Row of Planned Order, and Click on CONVERT TO PRODUCTION ORDER through this
Icon .
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Clicking on this, will take you to the Production Order Screen.

3. Quantity of Production
4. Basic Dates (As per the Scheduling Type)

1. Material Availability Check
It would show that the Material is available or not, if not it would mention that the material is shortage
and material need to be made available at the required storage location.
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Project VISION

2. Capacity Check
It would show whether the Capacity is Available or not.
Click on the Calculator on the Top Frame, to calculate the costs. Thereafter the system should
message as shown below.
Click on the Green Flag to RELEASE the Order.
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Project VISION
System would show that the Order has been released.

Now you can SAVE the production order and note the Production Order No.
Page 91 of 118
Project VISION
Refresh the Stock Requirement List (MD04) to see the Planned Order being now converted to status
Production Order (Shown in red box below).
Shop Floor Printing can be performed thereafter through Transaction Code: CO04N.
SAP ECC menu Logistics Production Shop Floor Control Control

Print
Page 92 of 118
Project VISION
14.4 PRODUCTION ORDER CONFN. WITH REWORK CO11n

Page 93 of 118
Project VISION
can now enter the ACTUAL Data which you have got through Production to be seen as the Variance
during the Production Order reporting.
As we would be doing REWORK activity in this Production Order, we can first check the Stock for the
part across the plant through T Code MMBE.
Page 94 of 118
Project VISION
On confirmation screen let us consider 200 as Yield Qty. and 100 as Qty. which is to be REWORKED.
Save the Confirmation

Now the material Qty. 200 has been posted to QA for Quality Inspection. The same can be checked in
the Stock Overview List of the FERT material.
Page 95 of 118
Project VISION
You can go back to CO02 for Production Order No. 100123 to see the status of the Qty.
Here you can see that out of the Total Qty. Delvrd is 200 and 100 is reworked which can be seen
through Operation Overview at the extreme Right End.
Page 96 of 118
Project VISION
14.5 PRODUCTION ORDER CREATION REWORK CO07

Create Without Material
PRE-REQUISITIES:
For Rework Order Following Pre-Requisites have to be followed.
1. A separate Rework Order has to be Created without Reference to any Material.

2. Goods Receipt for a Rework Order has to be done manually.
Page 97 of 118
Project VISION
Production Order Initial Screen will appear. Here enter Production Plant & Order Type for that Rework
Order.
GENERAL TAB
Thereafter on the Header Screen, Enter the following:
1. Material Description
2. Total Qty. to be reworked and Its Unit of Measurement
3. Basic Dates
Page 98 of 118
Project VISION
After giving ENTER it would give a Dialogue Box.
Here select on GENERATE OPERATION.

On the next Screen, i.e. Main Settlement Rule: Overview enter the following:
1. Category: ORD (i.e. to be settled against a Production Order)

2. Settlement Receiver: Production Order No. (In this case it is 1000123) & give ENTER.
Here it will now show the relevant details.
Go Back now.
Page 99 of 118
Project VISION
ASSIGNMENT TAB
Enter MRP Controller
Enter Profit Center
GOODS RECEIPT
Control Data: Stock Type ; X Quality Inspection
Thereafter Click on Operation Overview Icon

Select the following:
Work Center on which the rework is taking place
Control Key: PP07 (For Rework Production)
Can also enter the Operation Description and give ENTER.
Thereafter Click on Component Overview to enter the components to be processed.

Enter the Component to be reworked.
Enter the Quantity (can be calculated through CS11 for total requirement as per the rework
quantity).
After entering the details and giving ENTER it would ask for the Operation Assignment, i.e. the
component is to be assigned to which Operation. Select the operation and give Enter. Also
check for the Storage Location i.e. from where the Material will be issued, which should be
IS01 in our case.
Go back now.
Like a Normal Production, Check for Material Availability, Capacity Availability, Pre-Cost it and then
Release the Rework (Production) Order and Save it and note the Rework Production Order No.
Page 100 of 118

Project VISION
14.6 REWORK PRODUCTION ORDER CONFIRMATION CO11n

Page 101 of 118

Project VISION
need to enter the ACTUAL Data which you have got through Production as the same will not be copied.
Page 102 of 118

Project VISION
Now the material has been posted to QA for Quality Inspection. GR for the order needs to be done
manually.
Page 103 of 118

Project VISION
14.7 GOODS RECEIPT OF REWORK ORDER MB31
SAP ECC menu Logistics Production Shop Floor Control Goods

Movement Goods Receipt
NOTE: Goods Receipt for a REWORK Order has to be done manually. Auto GR is not possible.
Now, here enter the following:

Movement Type: 101
Order No. would be the parent Production Order, 1000123
Plant : 100
Storage Location : FG01
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Project VISION
After entering select the item No.1
Click on
And SAVE. You can see the Document No.
Page 105 of 118

Project VISION
You can go back to the Order 1000123 and see that all the 300 Nos. have been delivered.
Components are now posted to QA, which can be checked through MMBE
Hereafter the QA Cycle can be followed Index Point No. 11 to clear the Production Order.
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Project VISION
15. MRP FOR PLANNED ORDER + PURCHASE REQUISITION
So far we have seen MRP being run to generate PLANNED ORDER further to generate Production
Order to be run in Production environment. Now here we would see the MRP to be run to generate
Planned order as well as Purchase Requisition by a Single MRP Run through MD02.
MD02 is used to run MRP for a particular Material. This run would be for just one material , single item ,
multi level ( will explode whole BOM for particular material ).

Planning Single Item, Multi Level
Page 107 of 118

Project VISION
Here we take another Material as an Example.

FERT Material: TEST-FG12
Requirement in MD61 : 35 Qty.
First we check the existing Stock for TEST-FG12 through MD04.
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Project VISION
Enter the following details:

1. Enter Material Name
2. Enter Plant
3. Select Processing Key
Specifies the type of MRP run. The following types are possible:
net change planning: NETCH
net change planning in the planning horizon : NETPL
online regenerative planning : NEUPL
4. Create Planned Order / Purchase Requisitions (In case of BOP)
5. Delivery Schedules: Whether To Create or No
6. Create MRP List
7. Planning Mode & Scheduling
Above details are shown in the image above. ENTER to run the MRP.
An MRP List will be now generated.
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Project VISION
Now we go back to MD04 to check the Stock.
We can see that NO STOCK is available to Manufacture the FERT, shown as 0 in Available Qty. in
BLUE colour.
Click on the Eye Glass to get the new Dialogue Box.
Now click on to see the Order Report.
Page 110 of 118

Project VISION
Here you can see the Components which are contained in that FERT. And can Browse through, by
Double Clicking on the components to check the availability and the List below will show the latest
Stock position for that particular component.
Say we Click on IT-ROH03 (ROH material, whose Purchase Requisition is to be created).
Page 111 of 118

Project VISION
Here the one shown in RED Box, is the Planned Order which can be converted to Purchase
Requisition.
Click on Eye Glass.
Click on PUR. REQ. in the new dialogue Box. It will take you to Convert Planned order to Purchase
Requisition : Details Screen.
Here you can related information details such as, Storage Location (say ST01) and SAVE it. You will
get a Confirmation Message.
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Project VISION
REFRESH the list. Now you can see the List has been updated as shown in the RED BOXES below.
Further more, a PURCHASE ORDER can be created through PURCHASE REQUISITION. If release
Strategy has been set for Purchase Requisitions, the PR needs to be released before it is converted to
Purchase Order. This activity would be done by Purchase Dept. personnel.
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Project VISION
16. CO-PRODUCT SCENARIO
Products that are usually manufactured together can be produced using one production order.
The main product is the primary reason for the production process. It is displayed in the production
order header. The system also creates a separate order item for the main product.
A co-product is a product that is produced in conjunction with other products. The system creates a
separate order item in the production order for each co-product. As a result, it is possible to display
actual costs at co-product level.
Creating a production order to manufacture co-products has the following advantages:

Main product and co-product(s) are settled to different receivers
Goods movements can be posted simultaneously for all products manufactured in the order.
Pre-Requisities
The following prerequisites must be fulfilled if you want to create a production order with co-products or
by-products.
Prerequisite for the main product:

The indicator Co-product must be activated in the material master of the main product (MRP area)
Prerequisites for a co-product:

The indicator Co-product must be activated in the material master of the co-product (MRP area)
The co-product must be listed as an item in the bill of material of the main product with a
negative value.
On the Basic data tab page of the BOM item, the indicator Co-product must be activated in the
field group General data.
Example:
Say we have a Family Mould with 2 Family Components viz
1. TEST-COP01
2. TEST-COP02
Now say we want to take the Production of these 2 Family FERTs.
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Project VISION
Say we consider the Header / Main Product is TEST-COP01 we create a Production Order for this
Header Material.
BOM For TEST-COP01 would be as seen below.
Highlighted in Red is the Famiyl Component with ve (negative) Quantity.

When we check the Production Order it would show it as follows.
NOTE: GR for such an Order for a Co-Product scenario has to be done MANUALLY by MB31.
Also, whatever the Rejection / Scrap which is going to get posted will be of the Main Product whose
Production Order is being made.
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Project VISION
To Summarize:
1. A co-product is a product that is produced in conjunction with other products. The system
creates a separate order item in the production order for each co-product. As a result, it is
possible to display actual costs at co-product level.
2. The main product is the primary reason for the production process. It is displayed in the
production order header. The system also creates a separate order item for the main product.
3. The indicator Co-product must be activated in the material master of the main product (MRP 2)
as well as the Co-Product.
4. The co-product must be listed as an item in the bill of material of the main product with negative
Qty.
5. On the Basic data tab page of the BOM item, the indicator Co-product must be activated in the
field group General data.
6. Production Order would be of the Main Product, hence also the Confirmation and scrapping
would be of the Main Product Only.
7. Production Qty mentioned in the Production Order, say Qty. 10 means 10 Qty. of Co-Product 1,
and 10 Qty. of Co-Product 2.
8. Raw Material qty. to be issued would be the qty. required to product both the co-products.
9. In Production Order you need to maintain the settlement Rule in pull down menu i.e. Header ->
Settlement Rule
10. You cannot post Auto-GR for Co-Products. You have to follow Manual GR by MB31 101 Movt.
11. If you want to scrap co-product do the following steps.
Confirm all the qty as yield qty in . ( ok + scrap)
Do goods receipt for main product & co-product (total qty).
Physically you know the how much rejected qty. Move that qty from accepted str
location to rejection str location by using MB1B 311 mvt.
Now yield qty will reduce.
Check in MB51 with mvt type 311 with corresponding period, you came to know how
much quantities are rejected.
By 551 mvt materials scrap that rejected qty.
12. But if you want the Sell the scrap, then follow the following steps:
a. Confirm all the qty as yield qty ( ok + scrap)
b. Do goods receipt for main product & co-product (total qty).
c. Scrap the Material to a Scrap material, say SCRAP-MATERIAL through QA32 (QM).
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Project VISION
Suppose you have a Co-Product scenario for LH & RH of a particular FERT.
In this case you want to run only a few nos. of Cavity of RH keeping the nos. of cavities of LH running
as it is. In that case follow the below mentioned procedure.
Most important of all you need to maintain the Base Qty. relation of the 2 co-products.
Say for 4 Components of LH you want only 2 Components of RH. Here you need to maintain in BOM of
LH the following:
Select the Co-product with negative value (i.e. RH) and double click on Item No. to enter detail
information

Page 117 of 118

Project VISION
After entering, on the Basic Data Screen, maintain the negative Qty. as 0.50
Now you can go ahead and create the production order.

Now you will get only 2 Components of RH for 4 components of LH. Shown is the Production
Order.
One important thing to remember here is that the Cost apportionment is to be maintained
accordingly in Settlement rule.
Page 118 of 118

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Organization Sujan Barre Thomas Anti-Vibration Systems Pvt. Ltd.

END USER MANUAL

SAP, PRODUCTION PLANNING (PP) MODULE

SUJAN BARRE THOMAS ANTIVIBRATION SYSTEMS PVT. LTD.,

1 1.0 07-February-09 07-February-09 ---

Security Classification: COMPANY CONFIDENTIAL

1. CHECK SCHEDULING AGREEMENT MD04....................................................................................4

1. CHECK SCHEDULING AGREEMENT MD04

SAP ECC menu Logistics Production MRP Planning Evaluations

Here you can see the Scheduling Agreement inputted by SD.

2. CHECK STOCK OF MATERIAL - MMBE

SAP ECC menu Logistics Material Management Inventory

3. EXPLODED BOM VIEW CS11

SAP ECC menu Logistics Production Master Data Bills of Material

4.1a BY MANUAL CREATION THROUGH MB21

SAP ECC menu Logistics Material Management Inventory

Enter Movement No.: 311 for Plant 1000.

Note the Reservation No. shown in the System Status bar.

4.1b RESERVATION DISPLAY PRINT FOR INTIMATION MB25

SAP ECC menu Logistics Material Management Inventory

Enter Material & Plant 1000.

Reservation List Display will be seen.

Select Choose to select the saved Layout.

4.1c STOCK TRANSFER POSTING MB26

SAP ECC menu Logistics Material Management Inventory

Now the required material is available at IS01.

4.2 BY MANUAL CREATION THROUGH MB1B

SAP ECC menu Logistics Logistics Execution Internal Whse

Enter the following details on the main Screen viz.

On the next screen Enter the following:

And SAVE to post the material to the required Storage location.

5. CHECK BILL OF MATERIAL CS03

5.1 CHECKING STANDARD BOM

SAP ECC menu Logistics Production Master Data Bills OF Material

5.2 ADDING AN ALTERNATIVE BOM

SAP ECC menu Logistics Production Master Data Bills OF Material

To do so, CS01 can be used to create an Alternate over an Existing BOM.

6. CHECK ROUTING CA03

6.1 CHECKING STANDARD ROUTING

SAP ECC menu Logistics Production Master Data Routings

Transaction code CA03

Enter the Material Number & Plant to display the Routing.

operation and click on above.

For SBT Scenario we are using 3 Control Keys viz.

6.2 ADDING AN ALTERNATIVE ROUTING

To add an alternative routing you have through TCode CA01 itself.

SAP ECC menu Logistics Production Master Data Routings

Transaction code CA01

Here you can see the Counter as 2.

7. PRODUCTION ORDER CREATION MANUAL CO01

SAP ECC menu Logistics Production Shop Floor Control Order

Enter the following:

Enter the following:

in the top frame.

PRE-REQUISITE FOR PRODUCTION VERSION:

Now, Click on the following:

Click on the following:

It would show whether the Capacity is Available or not.