SAP Training

Training on
Production Planning-Process Industries
in SAP R/3

29-Dec-2008

Presentation By: Prasanna

AGENDA
Agenda

Production types in SAP system

Application of PP-PI
PP-PI Basic Data
PP-PI Vs Standard PP
Data flow in PP-PI
Resource
Master recipe
Planning levels
MRP overview
Process order cycle
Special features available in PP-PI
Production Types in the SAP System

Discrete manufacturing
Process industries
Lot
Lot Lot

Work center 2
Work center 1 Work center 3

Repetitive/Flow manufacturing KANBAN Supply source

full

full
full Procurement

Production line
Demand source
Production Types in the SAP System

Discrete Manufacturing
Can be implemented when the plant layout Is process based.

Repetitive Manufacturing
Can be implemented when the plant layout Is product based

KANBAN
Can be implemented when the plant layout Is Cell based or
demand-supply based

PP-PI Manufacturing
Can be implemented when the plant layout Is product based
and also interface exist with other MES / DCS
Application Areas of PP-PI with Target Markets

Chemical
Industry

Process Batch
Mfg. Production

Batch and By-Products

Production PP-PI
Records Co-Products

Variable Fully and

Food Partially Pharma-
Production Automated ceutical
Industry Parameters Industry
Lines
PP-PI Basic Data

Master Recipe

Materials Resource

Production Facilities Production

PP Basic Data Resources/Tools

Inspection Capacities
Plans
BOM / Material list
PP-PI vs. Standard PP

PP-PI Standard PP

Resource Work Center

BOM
Master Recipe
Routing

Production
Process Order
Order
Data Flow in PP-PI

Other Message Process

Destinations Process Planning
Order

s
s sa s

Co cipe
ge
Me oces

Re
ntr
Process
Management
Pr

ol
PC Sh

Process
PI

nt ss
S ee

Control

l
Co oce
ro
Pr
t

Execution
Data Flow in PP-PI

Process planning’s main functions are to schedule operations in process orders, to check
material availability as well as to release process orders for production.

Process management is the component which interfaces with process control systems.
The flexible structure of process management makes it possible to link up to automated,
partially automated and manually driven plants. Process management includes the
following functions:
Creation of control recipes from process orders
Distribution of control recipes to the line operators or process control systems
involved
Receiving, checking and distributing process messages with actual data on a
process
Manual entry of process messages

A control recipe contains all the process instructions necessary for the execution of a
process order by a process control system or a line operator. Control recipes are
generated from the process instructions in a process order and sent to the corresponding
process control system. One control recipe is generated for each control recipe destination
defined in the
process order.
Primary Functions of a Resource

Resource

Scheduling Data
Default Values Costing and Available
for Task Lists Data Capacity

Lead Time Scheduling,

Task Lists Costing Capacity Planning

2724,00
1200,00
124,00
4048,00
Master Recipe Structure

Resource Network
Recipe Header

Material List
Operations

Resource Allocations
Phases
Mat

Material
----- ------ -------
----- - ----- --
------- ------- ---------

Material
Components
Process Instructions

Relationships
PI Characteristics

Inspection Characteristics
Planning Levels

CO/PA
Profitability Region 1 Region 2
SIS Forecast
analysis

SOP
Sales & operations
Product group
planning

Feedback / Corrections
Demand Product 1 Product 2
management

MPS
Master production Long-term
scheduling planning
Production planning

MRP
Assembly Assembly
Material
requirements ..
planning
Part
.
MRP Overview

Sales
Material Reqmts
Orders
Planning
Planned Ind
Dependent Reqmts Requirements

Reservations
Planned Order

Convert

Purchase Schedule
Production Requisition Line
Order

Purchase Order
Warehouse
Process order Cycle in SAP

Process Order Management

Archiving / Deleting Planned orders

MR
Process data
s ing P
Process order
documentation o creation
cl
er

Pr
Process order Proc. order
Ord

o
settlement Scheduling

ce ss
Operations
Cap. requirements

planning
Phases
planning
Goods receipts
Process

Resource
assignments
Process Material availability
instructions Material check
components
Proc. messages

nt
Costs
for diff. destin . Relationships

me
Relationships Release of
ord

process order

ge
In - process a
er

quality inspections ex an Creating & downloading

e c m
ut es s control recipes
Confirmations ion
/ Proc
for order Material withdrawals
Processing Procedure

Process Order Demand

Process Order Creation

Availability Check

Process Order Release

Control Recipe Creation

Material Withdrawal

Process Order Execution

Completion Confirmation

Inward Stock Movement

Mat
Mat

----- ------ -------

----- - ----- --
------- ------- ---------
Process Order Settlement
Material
Archive / Delete
Special features of PP-PI

Storage Resource

Resource Network

Material Qty Calculation

System Aided resource selection

Production Campaign

Co-Product

Batch-wise costing

Intra Material

Process management
Storage resource

A storage resource is a storage location or production unit that has both the
characteristics of a resource and a storage location. It is used for
intermediate storage of materials.

There are two types of storage resources:

Storage resource, on which no production process takes place (resource

category Storage) This storage resources can have an available capacity and
material stock assigned to it. Its available capacity is defined in the unit
volume/quantity.

Storage resource, at which a production process takes place (resource

category Processing unit / Storage) This storage resources can also be
planned as far as time is concerned and material movements take place on it.
Its available capacity is defined both in a time unit and in volume/quantity.
Resource network

A resource network describes the physical links

between resources such as processing units of a line
(vessels, reactors).

It describes the flow of materials through a line or plant

You use resource networks in process planning when

you want to specify in which sequence the resources can
be used in production.

Resource networks are used in the process order during

resource selection.
Material Qty Calculation

We can use this function for a production version of a master recipe or a process order to visually
produce the dependencies between the following values:

Quantity and properties of a product, such as the active ingredient proportion

Quantity and properties of material components, that is, material items and their batches

Operation and phase quantities

The scrap to be expected for an operation or phase

To adjust the quantities defined in the bill of material (BOM), master recipe, or process order.
(Depending on the active ingredient concentration of a component batch, you may need, for
example, different quantities of another component, that is used as a filling material)

Pre-requisites:
To be able to use material quantity calculation in a master recipe, you must have defined a
production version for the master recipe.
To transfer the data from material quantity calculation from a master recipe to the process
order, you must create the process order with the corresponding production version.
To transfer the scrap calculated in material quantity calculation to the corresponding phase
in the process order, you must have activated scrap management in the parameters of the
relevant order type
Production Campaign

This component addresses the needs of discontinuous production in companies in process industries that
manufacture sequences of identical production charges on their production lines. You can manage batch
manufacturing using production campaigns.
The aims of campaign management are the following:
Reduced costs achieved by grouping sequences of identical production charges and thus carrying out
more efficient setup and clean-out processes which can be very costly
Higher product quality in cases where the desired quality level is achieved gradually in the production
process as opposed to immediately from the first batch
More exact settlement resulting from clear distribution of campaign fixed costs (setup, clean-out, and
teardown costs) to the orders involved
Co-Product

Products that are usually manufactured together can now be produced using
one process order, but with separate settlement.

One product is regarded as the main product and the remaining products are
described as co-products. The system automatically creates a separate order
item for each of the co-products.

The following applies to process orders with co-products:

You can settle the main product and the co-product(s) to different receivers

Goods movements can be posted simultaneously for all products

manufactured in the order.
Batch-wise costing

This features enables the system to main the cost of each batch
manufactured based on the value of the key characteristics.

Priority customer can be served more precisely with this.

Intra-Material

Intra material – Material exists temporarily between operation of a process

Thank you