Materials Setup in FCS V6 (ENHANCED Version) PDF

Scheduling & Pull system
Materials setup in FCS
9th of March 2016 (V6)

Functional macro process
PURCHASING SALES
Contract LOGISTICS Contract
Material Integration
Procurement of the
Levelling requirements PDP PIC
program customer
planning
demand
Supplier Customer
LOGISTICS PRODUCTION LOGISTICS
Transfer
Goods Production Production Shipment
to
receipt production declaration
METHODS / ENGINEERING
Inventory
Product mBOM Creation of
QUALITY definition management work centers Inventory CONTROLLING
in FCS in FCS and routings
in FCS
Materials setup in FCS V6 4

Creation of materials in FCS
Hierarchical structure of the data

 Company structure Faurecia
(Group) Corporate
1 Transfer
2 PO + delivery note
Company Company
FR23 FR29
FII FSE Legal entity
(FIS) (FECT)
Plant 1256 (Saint Michel)

FR23_I_SSM_1256 Plant 1258 (Meru)
1 FR23_I_MER_1258 PlantPlant
1724 (BSO) BAU
Plant
1251
FR23_I_SJP_1724
1251
2 Meru FORD-BAU-IS-ICM-RD
Meru FORD-BAU-IS-ICM-RD
Incoming Production Outbound Jail External Incoming
area area area area warehouse area Storage
IN10 PR10 OU10 JA10 EX10 IN10 locations
 Material master data are defined in one single, common and shared database for all plants in FCS:
 A same material used in multiple plants has the same part number and material type.
FCS storage locations

1. IN10: Inbound storage
location (BOP and RM).
2. PR10: Production shop

floor (BOP moved from
central warehouse IN10 and
Semi-finished goods).
3. OU10: Production shop

stock, TPA, Pool stock,
internal Security stock
(Finished Goods).
The 3 above storage

locations are included in the
MRP calculation.
4. JA10: Jail or Quality

quarantine (non-usable
material). Material in JA10 is
not included in MRP as
 Work instruction: FAU-I-PSG-6601 Standard Storage Locations
available.
Instruction (not printed)
FCS material types

 ‘COMP’: BOP, RM and disposable packaging Material types processed
through MRP, declared,
 ‘SFIN’: inter/co BOP, semi-finished, FG and phantoms
backflushed, etc.
MM01 FCS transaction
 ‘NOST’(Non-stock material): ie Transport route
 ‘NOVA’ (Non-value material): ie Consigned parts, tools belonging to Cust.
 ‘PACR’ (Returnable packaging): allow to track stock and value at Faurecia, Supplier
& Customer
 ‘PACK’ (Packaging): allow to track stock and value at Faurecia
 ‘PACN’ (Non-stock packaging): no stock nor value tracking
 ‘CRIB’ (Spare & Maint. Parts) = ‘SFIN’
= ‘NOST’
= ‘PACN’
 Special cases: = ‘NOVA’
 Interco (material sold by a Faurecia plant and bought by another Faurecia plant): it = ‘PACK’
must be created as ‘SFIN’ in both FCS plants.
 Pass through part (BOP sold to a Customer without any added value, except = ‘COMP’
repacking and relabelling): must be created as ‘SFIN’. = ‘PACR’
= ‘CRIB’
 Sub-contracting: Part nb 1: Material shipped to third party must be created as
‘COMP’ or ‘SFIN’ (depending if it is a BOP/RM or manufactured at Faurecia).
Part nb 2: Material received from third party must be created
as ‘SFIN’ with special procurement type « 30 ».
FCS material types

 Tip: in order to display the technical names in Material Type drop-down list:
SAP logon → Settings → Interaction Design → Visualization 1 → match the screen shot selections below → OK
Technical
names

Methods to create materials

 There are 3 different ways to create Material master data in FCS:
 By migration activities from other ERP systems to FCS when FCS is implemented at the plant
 Through PDM (Product Data Management System) interface in preparation to the launch of a new program
or per engineering change request
 Directly in FCS using engineering department information
FCS rollout team:
Migration from Legacy Systems (BPCS, XPPS,
etc.) to FCS
Manufacturing Engineer: Manufacturing Eng

MCO: Manufacturing Change Order Create & maintain “Material Finance/Controlling
Creation of material Basic Data views directly on Basic Data Views and Update related views
Engineering:
FCS Classification views (MM01/MM02)
ECR: Engineering Change request
(MM01/MM02)
ECO: Engineering Change Order Manufacturing Engineer:
MCO: Manufacturing Change Order
Creation of material Basic Data views directly on Purchasing
PDM &Transfer PDM to FCS Logistics
Update related views
Create & maintain (MM01/MM02)
“Manufacturing data (MRP
views) (MM01/MM02)
Sales
Logistics
Update related views
Create & maintain “Storage Data
(MM01/MM02)
Views (MM01/MM02)
SAP Material
master
PC&L responsibility
PC&L Responsibility
Material data
Sales Materials Batch views
Sales Price classification management
Order Examples of
Elements Directly
involved
Sales views Classification
view
Not used in FCS
Purchase Purchasing Product

Order views Costing price
Basic data views definition
1,2
Views Accounting Financial
Material MRP 1,2,3,4
Planning views views bookings
Quality management
Work scheduling views
views Plant
data / storage 1,2 Quality
Production views control
Order
Stock
Traceability
views
FCS setup per material type

X = views to be created in FCS
 : PC&L responsibility
Source: FCS-PC01-CD- Define Product in ERP

FCS Manufacturing views – to be filled by PC&L
MM01: MRP 1 to 4 views

 Work instruction: FCS-PC01-WI-ManufacturingDataViews
o This work instruction explains:
 how to create MRP views 1, 2, 3 and 4 for a material,
 how to create MRP views 1, 2, 3 and 4 by copying from another material,
 how to update MRP views 1, 2, 3 and 4 for a material.
o Target: Understand
 How to create / update a material
 How to select the Material type
 The impacts of : MRP profile
Strategy group
MRP type, Planning time fence
Lot size, Planning calendar
Minimum lot size, Rounding value
Safety stock, Safety time
MM01: MRP 1 to 4 views - FCS PC&L setup for materials
Base Unit of Measure
Assembly scrap
Rounding value
Valuation Class
Strategy group
GR Proc. Time
Pl. Deliv. Time

Max. Lot Size
Material Type
Fixed lot size

Min. Lot Size
MRP profile
MRP Group
MRP Type
Backflush
Lot size
Material Description
Z00-Finished Non JIS non PDP SFIN 6000 0003 M0 40 0003 (1) EX (1) blank blank 0 (1) 0 0
Z01-Finished (Prodtn Non JIS) SFIN 6000 0001 M0 10 0001 (1) EX (1) blank blank 0 (1) 0 0
Z02-Finished (JIS) SFIN 6000 0003 M0 10 or 40 (1) 0003 (1) EX blank blank blank 0 blank 0 0
Z05-Trade parts SFIN (1) (1) (2) 0000 P1 or PD (1) 40 0000 (1) EX or PK (1) (2) blank blank 0 (1) 0 0
Z04-Phantom SFIN 5000 0003 M0 40 0005 (1) EX blank blank blank 0 blank 0 0
Z03-Semifinished goods SFIN 5000 0003 M0 40 0003 (1) EX (1) blank blank 0 (1) 0 0
Set by default
Z08-SemiFin (LISA) Int Flow SFIN (2) 4500 0000 P1 blank 0000 (1) EX or PK (1) (3) blank blank 0 (2) 0 0
Z09-SemiFin (Non LISA) Int Flow SFIN (2) 4500 0000 P1 blank 0000 (1) EX or PK (1) (2) blank blank 0 (1) 0 0
Z06-Comp (LISA) COMP (2) (2) 0000 P1 blank 0000 (1) EX or PK (1) (3) blank blank 0 (2) 0 0
Z07-Comp (Non LISA) COMP (2) (2) 0000 P1 blank 0000 (1) EX or PK (1) (2) blank blank 0 (1) 0 0
Z10-Comp (LISA) Special Flow COMP (2) (2) 0000 P1 blank 0000 (1) EX or PK (1) (3) blank blank 0 (2) 0 0
Z11-Comp (Non LISA) Special Flow COMP (2) (2) 0000 P1 blank 0000 (1) EX or PK (1) (2) blank blank 0 (1) 0 0
Z12-Components (JIS) LISA COMP (2) (2) 0000 P1 blank 0000 (1) EX or PK (1) (3) blank blank 0 (2) 0 0
Z13-Components (JIS) non LISA COMP (2) (2) 0000 P1 blank 0000 (1) EX or PK (1) (2) blank blank 0 (1) 0 0
 For specific cases, ask helpdesk

Plant-sp.matl status
Safety time in days
SpecProcurement
SchedMargin key
MRP dep. reqmts

SelectionMethod
DF at plant level
Quota arr.usage
Plng time fence
InhseProdTime
Safety time ind
Repetitive mfg
Plng calendar
Procurement
Safety Stock
Avail. check
Do Not Cost
REM profile
Neg. stocks
Indiv./coll.
Material Description
Z00-Finished Non JIS non PDP (1) blank blank X 1 E 0 blank blank 0 blank 000 KP 2 2 blank Z004
Z01-Finished (Prodtn Non JIS) blank (2) blank (2) blank (2) X 1 E 0 blank blank 0 blank 000 KP 2 2 1 Z004
Z02-Finished (JIS) blank blank blank X 1 E 0 blank blank 0 blank 000 KP 2 2 blank Z004
Z05-Trade parts (1) (1) (1) X blank F (1) blank 4 0 (1) 000 KP 2 2 blank blank
Z04-Phantom blank blank blank blank 1 E 0 50 blank 0 blank 000 KP 2 2 blank Z004 X
Z03-Semifinished goods (1) blank blank X 1 E 0 blank blank 0 blank 000 KP 2 2 blank Z004
Z08-SemiFin (LISA) Int Flow (1) (1) (1) X blank F 1 blank 4 0 (1) 000 KP blank 2 blank blank
Z09-SemiFin (Non LISA) Int Flow (1) (1) (1) X blank F (1) blank 4 0 (1) 000 KP blank 2 blank blank
Z06-Comp (LISA) (1) (1) (1) X blank F 1 blank 4 0 (1) 000 KP blank 2 blank blank
Z07-Comp (Non LISA) (1) (1) (1) X blank F (1) blank 4 0 (1) 000 KP blank 2 blank blank
Z10-Comp (LISA) Special Flow (1) (1) (1) X blank F 1 (1) 4 0 (1) 000 KP blank 2 blank blank
Z11-Comp (Non LISA) Special Flow (1) (1) (1) X blank F (1) (1) 4 0 (1) 000 KP blank 2 blank blank
Z12-Components (JIS) LISA (1) (1) (1) X blank F 1 blank 4 0 (1) 000 KP blank 2 blank blank
Z13-Components (JIS) non LISA (1) (1) (1) X blank F (1) blank 4 0 (1) 000 KP blank 2 blank blank
 For specific cases, ask helpdesk


FCS fields # Comments
(1) Trade parts can also be "COMP".
Material Type When BOP/RM is purchased from an external supplier, material type is "COMP".
(2)
When BOP/RM is purchased from another Faurecia, material type is "SFIN".
Never use class "4010", not even for Trade parts because if at some point we need to use the same component to
(1)
Valuation class be consumed in one of the internal parts, it is not possible anymore.
(2) According to Controlling standard table. This is set by controlling not by PC&L.
Strategy group (1) If the plant want to run PIC & PDP on this FG: use "10". Otherwise "40".
Base Unit of Measure (1) Mandatory
"EX" (when the supplier deliveries at Faurecia are scheduled everyday) or "PK" (when the supplier deliveries at
Lot size (1)
Faurecia are not scheduled everyday).
(1) According to packaging lot size
Min. Lot Size (2) Is equal to the minimum quantity to order from the supplier
(3) Is mandatory and equal to the Rounding value
(1) Rounded by the packaging lot size (SFIN) or by the multiple quantity of pieces to order from the supplier (BOP/RM).
Rounding value
(2) Is mandatory and equal to the Min Lot Size
BOP/RM: Safety stock can be set up and must be updated regularly to avoid shortage, overstock and
obsolescence.
(1)
Safety Stock FG (non managed with PDP) and semi-finished: Safety stock can be set up, depending on the needs and process
of the plant.
(2) Forbidden as the stock is taken in account in the PDP arbitration
(1) Enter the value "2" to use the Safety time option. Leave blank if not
Safety time Indicator
(1) Using the Safety time option moves forward the requirements of the number of days entered in this field.
Safety time (in days)
Auto PO (1) For Trade parts: check with Purchasing if Automatic PO should be selected
When "P1" is selected as MRP type, a Planning time fence must be entered. It is the number of working days
Planning time fence (1) during which no change to the MRP is done. It must match the Firm zone (in calendar days) of the scheduling
agreement.
Special Procurment (1) Special flow is subcontracting or consignment: "10" for consignment, "30" for subcontracting, "50' for Phantom.
When "PK" is selected as Lot size, a Planning calendar must be entered. It is the delivery days at Faurecia for the
Planning calendar (1) supplier. Use match code to see the different Planning calendars available.
When "EX" is selected as Lot size, leave field blank.

MM01: Plant data / stor. 1 & 2 views

 Plant data / stor. 1
If you do not want

FCS to assign a
class (A, B or C)
Plant code to the material
according to
future
consumption
Storage Bin: value: enter the
used for LISA and e- class yourself and
Kanban materials flag “CC fixed”.
(printed on Manifest
and labels)  A/B/C classification
is used to define cycle
count frequency (A
parts are counted
Always D monthly, B every 3
months, C every 6
months)

MM01: Plant data / stor. 1 & 2 views

 Plant data / stor. 2
Data coming from

Basic Data View 1
(Engineering
department) –
printed on labels
Why?
Flag to authorize
Plant Code

MMSC: extend Storage locations for a material

 Extend = allow a material to be stored in the
listed FCS locations.
 If a user transfers a material from one location to
another for which the material has not been
extended to, transaction will fail and create inventory
inaccuracy.
1. Go to transaction MMSC
2. Enter the material number you want to extend locations
3. Enter the Plant code number
4. Check the box «Create change documents». This will
send the information of the new material to MII.
5. Hit Enter key
6. In the next screen enter the locations where this material
is allowed to be located (usually IN10, PR10, JA10 for
BOP/RM; PR10, JA10 for semi-finished and OU10, JA10 for
FG)
When a part number is
7. Hit Enter key extended to a storage
location, it is impossible
8. Save to change it
MMSC: extend Storage locations for a material

 Stock in certain location is excluded for MRP
calculation:
o Location(s) excluded from MRP calculation is
defined with a ‘1’ on MMSC transaction.
o It can default with a ‘1’, depending on the plant
setup. JA10 usually defaults to ‘1’.
o If set in error, it must be removed using MM02
transaction, by storage location → remove the
‘1’ in «SLoc MRP indicator» field.

FCS Manufacturing views – to be filled by PC&L (if not already done by Manufacturing Eng.)
MM01: Classification view

 Specifythe class of a material in order to assess its master data completion status.
Warnings will be done based on the expected setup for its class.
 Work instruction: FCS-PC01-WI-Create_and_MaintainMaterialBasicData.pdf

FCS Manufacturing views – to be filled by PC&L (if not already done by Manufacturing Eng.)
MM01: Classification view
Available classes:

FCS Manufacturing views – Material master data report
ZMM_MASTERDATA: report based on Classification view

 ZMM_MASTERDATA transaction produces a report to highlight if a material (COMP or
SFIN) is complete or missing data.
 Work instruction: FCS-PC01-WI-Material_Master_Creation_Cockpit.pdf

FCS Manufacturing views – Material master data report
ZMM_MASTERDATA: report based on Classification view

Exercise: update MM02, ME32L & MMSC with the following data
 Plant code: 1150 (Olmedo)  Division: 12
 Sales organization: IS03  The plant works 5/7 days
PC&L trainer:
BOP example (NON LISA)

Part # 1157003E is purchased from KNAUF MIRET.
The agreement is to buy a minimum of 1000 pcs
then by multiple of 100 pcs. The supplier requests 3
weeks of firm releases.
The delivery is planned at Faurecia on Mondays and
Thursdays (code = 119).
Faurecia defines it is necessary to always keep 200
pcs in house.
LISA process is not used.

Exercise: update MM02, ME32L & MMSC with the following data
 Plant code: 1150 (Olmedo)  Division: 12
 Sales organization: IS03  The plant works 5 days out of 7 days
Group 1:
Part # 116018E is purchased from NEDSCHROEF. The agreement is to buy a minimum of 1 complete pallet at each order (600 pcs), then by multiple
of a layer (60 pcs). The supplier requests 4 weeks of firm releases (2 weeks preparation time + 2 weeks transit time).
The delivery is planned at Faurecia on Mondays, Wednesdays (code = 106). Faurecia defines it is necessary to always keep 600pcs in house.
LISA is not used.
Group 2:
Faurecia Olmedo (Customer) has an open PO for part # 1162044E with Faurecia MORNAC (Supplier). Although this part is not used very much it is
very critical to have an accurate stock of it so the plant chose to cycle count it every month. The Material planner decides to keep 20 pcs on hand all
the time and must order a minimum quantity of 100 pcs. Purchasing and the supplier agreed on 2 weeks firm order. Delivery is scheduled every day.
Box quantity is 10 pcs. LISA is not used.
Group 3: (for participants used to LISA)

Part # 101162E is purchased from ACOUSTICS AND INSULATION TECHNIQUE. The agreement is to buy a minimum of 1 complete pallet at each
order (200 pcs). The supplier requests 1 week of firm releases (preparation time + transit time).
The delivery is planned at Faurecia on Mondays, Wednesdays and Fridays. Faurecia defines it is necessary to always keep 200pcs in house.
LISA is used.
Group 4:
Faurecia Olmedo send parts to be painted to BORGERS. Parts (# 1144015E) are then ordered from this sub-contractor to be used in production.
Although this part is not used very much it is very critical to have an accurate stock of it so the plant chose to cycle count it every month. The Material
planner decides to keep 50 pcs on hand all the time and must order a minimum quantity of 100 pcs. Purchasing and the supplier agreed on 4 weeks
firm order. Delivery is scheduled every Monday. Box quantity is 10 pcs. LISA is not used.
Group 5: (for participants used to LISA)

Part # 101178E is purchased from ACOUSTICS AND INSULATION TECHNIQUE. The agreement is to buy a minimum of 1 complete pallet at each
order (50 pcs). The supplier requests 2 weeks of firm releases (preparation time + transit time).
The delivery is planned at Faurecia on Mondays and Fridays. Faurecia defines it is necessary to always keep 100pcs in house. LISA is used.

FCS Manufacturing views – report 1
ZPP_MATMM: synthetic report of material master data
Select Logistics
Data
Press
Enter
Enter Plant
Enter Material
Number

Change file to « .xls »

Planning Procure ABC Special Base Planning Quota GR Planned Safety Neg. CC
Material strategy Material MRP MRP ment Indic MRP procure Unit of time MRP Lot Minimum Rounding arr. In-house Processing Deliv. Planning Safety Safety time/act. Availability Selection Individual Repetitive REM stocks Profit phys.
Material Description group Type group profile type ator Type ment Plant Measure fence Controller size Lot Size value usage Backflush production Time Time calendar Stock time ind. cov. check method /coll. mfg profile in plant Center inv. ind.
4065291 Heat Shield 0 COMP 0000 0000 F P1 1512 PC 1 001 EX 40,000 40,000 4 1 0 0 1 120 02 3 KP 2 2 X Z004 X 1512 C
4065293 Button head screw 0 COMP 0000 0000 F P1 1512 PC 1 001 EX 3 000,000 3 000,000 4 1 0 0 10 101 02 10 KP 2 2 X Z004 X 1512 C
4065301 Hot End Isolator Assy 0 COMP 0000 0000 F P1 1512 PC 1 001 EX 1 620,000 1 620,000 4 1 0 0 1 100 2400 2 1 KP 2 2 X Z004 X 1512 C
4065315 Outlet Pipe 0 SFIN 0000 0000 F P1 1512 PC 1 001 EX 40,000 40,000 4 1 0 0 0 105 02 1 KP 2 2 X Z004 X 1512 C
4065316 2.5L Sensor Boss 0 COMP 0000 0000 F P1 1512 PC 1 001 EX 210,000 210,000 4 1 0 0 1 103 400 2 1 KP 2 2 X Z004 X 1512 C
4065447 Single Brick Converter Body0 COMP 0000 0000 F P1 1512 PC 1 001 EX 80,000 80,000 4 1 0 0 6 105 02 3 KP 2 2 X Z004 X 1512 C
4065448 2.5L Outlet Pipe 0 SFIN 0000 0000 F P1 1512 PC 1 001 EX 15,000 15,000 4 1 0 0 1 105 100 2 1 KP 2 2 X Z004 X 1512 C
4068783 3.6L Cold End Inlet Pipe 0 SFIN 0000 0000 F P1 1512 PC 1 001 EX 100,000 100,000 4 0 0 1 105 100 2 1 KP 2 2 X Z004 X 1512 C
4068784 3.6/1.8L Front Hanger 0 COMP 0000 0000 F P1 1512 PC 1 001 EX 60,000 60,000 4 1 0 0 1 105 1000 2 1 KP 2 2 X Z004 X 1512 C
4068785 3.6L Intermediate Muffler 0 SFIN 0000 0000 F P1 1512 PC 1 001 EX 32,000 32,000 4 1 0 0 1 64 0 KP 2 2 X Z004 X 1512 C
4068820 3.6L Y-pipe Splitter 0 COMP 0000 0000 F P1 1512 PC 1 001 EX 100,000 100,000 4 0 0 0 150 2 1 KP 2 2 X Z004 X 1512 C
4068824 3.6L LH Rear Muffler 0 SFIN 0000 0000 F P1 1512 PC 1 001 EX 48,000 48,000 4 0 0 0 80 0 KP 2 2 X Z004 X 1512 C
4068836 3.6L RH Rear Muffler 0 SFIN 0000 0000 F P1 1512 PC 1 001 EX 48,000 48,000 4 0 0 0 80 0 KP 2 2 X Z004 X 1512 C
4068896 Mounting Assy 0 SFIN 0000 0000 F P1 1512 PC 1 001 EX 40,000 40,000 4 0 0 1 103 8000 2 10 KP 2 2 X Z004 X 1512 C
4068897 Isolator 0 SFIN 0000 0000 F P1 1512 PC 1 001 EX 100,000 100,000 4 0 0 1 103 8000 2 10 KP 2 2 X Z004 X 1512 C
4068898 Mounting Assy 0 SFIN 0000 0000 F P1 1512 PC 1 001 EX 42,000 42,000 4 0 0 1 103 8000 2 10 KP 2 2 X Z004 X 1512 C
4069175 2.5/2.0L Front Hanger 0 COMP 0000 0000 F P1 1512 PC 1 001 EX 60,000 60,000 4 1 0 0 1 105 800 2 1 KP 2 2 X Z004 X 1512 C
4069238 2.5L Rear Muffler 0 SFIN 0000 0000 F P1 1512 PC 1 001 EX 26,000 26,000 4 1 0 0 1 115 2 1 KP 2 2 X Z004 X 1512 C

Select Storage
Location
Press
Enter
Enter Plant
Enter Material
Number


 Same way than ‘Logistics data’ to export results to excel
Same part number: 1 row per set up FCS storage location
Plant Material Valuation DF at Plant-sp.matl Material Description Base Unit Material Storage Storage MRP ABC Label Label Neg. stocks Profit Year Current Phys. Inv. Unrestricted Date of Last Stock in Blocked Returns
Class plant level status of Measure Type Location Bin Controller Indicator type form in plant Center current period Block Count transfer
1512 957535 7000 48 x 45 pallet EA PACK 999 1512 period 0 0,000 0,000 0,000 0,000
1512 957550 7000 48 X 45 X 34 EA PACK EA10 BIN 1 999 C X 1512 2011 8 0,000 24/08/2013 0,000 0,000 0,000
1512 957550 7000 48 X 45 X 34 EA PACK EX10 BIN 1 999 C X 1512 2011 8 0,000 24/08/2013 0,000 0,000 0,000
1512 957550 7000 48 X 45 X 34 EA PACK IN10 BIN 1 999 C X 1512 2011 8 0,000 24/08/2013 0,000 0,000 0,000
1512 957550 7000 48 X 45 X 34 EA PACK JA10 BIN 1 999 C X 1512 2011 8 0,000 24/08/2013 0,000 0,000 0,000
1512 957550 7000 48 X 45 X 34 EA PACK JA20 BIN 1 999 C X 1512 2011 8 0,000 24/08/2013 0,000 0,000 0,000
1512 957550 7000 48 X 45 X 34 EA PACK OU10 BIN 1 999 C X 1512 2011 8 0,000 24/08/2013 0,000 0,000 0,000
1512 957550 7000 48 X 45 X 34 EA PACK PR10 BIN 1 999 C X 1512 2011 8 0,000 24/08/2013 0,000 0,000 0,000
1512 957621 7000 LAYER PADS EA PACK EA10 BIN 1 999 C 1512 2011 8 0,000 24/08/2013 0,000 0,000 0,000
1512 957621 7000 LAYER PADS EA PACK EX10 BIN 1 999 C 1512 2011 8 0,000 24/08/2013 0,000 0,000 0,000
1512 957621 7000 LAYER PADS EA PACK IN10 BIN 1 999 C 1512 2011 8 0,000 24/08/2013 0,000 0,000 0,000
1512 957621 7000 LAYER PADS EA PACK JA10 BIN 1 999 C 1512 2011 8 0,000 24/08/2013 0,000 0,000 0,000
1512 957621 7000 LAYER PADS EA PACK JA20 BIN 1 999 C 1512 2011 8 0,000 24/08/2013 0,000 0,000 0,000
1512 957621 7000 LAYER PADS EA PACK OU10 BIN 1 999 C 1512 2011 8 0,000 24/08/2013 0,000 0,000 0,000
1512 957621 7000 LAYER PADS EA PACK PR10 BIN 1 999 C 1512 2011 8 0,000 24/08/2013 0,000 0,000 0,000
1512 978264 7000 BUBBLE WRAP EA PACK EA10 BIN 1 999 C 1512 2011 8 0,000 24/08/2013 0,000 0,000 0,000
1512 978264 7000 BUBBLE WRAP EA PACK EX10 BIN 1 999 C 1512 2011 8 0,000 24/08/2013 0,000 0,000 0,000
1512 978264 7000 BUBBLE WRAP EA PACK IN10 BIN 1 999 C 1512 2011 8 0,000 24/08/2013 0,000 0,000 0,000

FCS Manufacturing views – Mass update
ZMM_MASS: update in mass some MRP parameters

 Select « Materials (Industry) », enter the plant code and the
list of part numbers (ou directly a part family) to affect the
same parameters.
 Select the parameters to be updated and the new value.

It is possible to update multiple parameters in the same time.
Example:
 Work instruction: FCS-PC01-WI-SAP-Material_Mass_Updates

This transaction can also be used to mass update Purchasing scheduling
agreements.
BOM: Bill Of Materials
How to create BOM?

 Engineering creates the eBOM, which
is then used to setup the BOM in FCS
In FCS, a BOM is created using

FG

Level 0
transaction CS01, level by level
 Base 1000: the number of pieces of a

child necessary to make 1000 pieces
of parent must be entered
Level 1 A x2
B x1
 At the launch of a new program, a

theoritical quantity of child for 1000
parent is entered
Level 2 C x1
D x3
 it must be updated once in production
to account for technical scrap and
process inefficiency
 BOM must be audited per FCP

Phantom
Level 0
Level 1
Level 2
Level 3
A phantom represents a set of BOP / RM / semi-finished materials which are

used in multiple semi-finished or FG. This practice reduces time required to build
semi-finished / FG BOMs and also reduces opportunity for error.
A phantom level does not maintain stock nor show planning in FCS
(PIC/PDP/MRP) so do not set up as phantom a material which needs to be
declared and whose stock value must be known.
Phantoms can be used to ease scrap declaration.

Technical scrap Vs Operational scrap

 Technical scrap:
 Is part of how the process is set up,
 Affects every single part (injection sprue, painting / gluing overspray, vinyl lazering / cutting yield, etc.)
or is periodic (injection purge, painting / gluing gun change, lazering / cutting start & end of a roll, etc.).
 Technical scrap must be taken into account in MRP and in backfush.
 To do so automatically, the BOM qty must include this technical scrap (CS02).
 FCP: FAU-S-LSG-3204
 Operational scrap:
 Is not part of the standard process,
 Is due to human mistake (fasteners fallen on the floor, bigger injection purge than standard, etc.) or decision (to not use
the end of a roll because it is too short and would require additional operations, etc.).
 Operational scrap must be taken into account in MRP and scrapped manually in FCS when it occurs.
 A % must be enterred in ZJPP04 to take it into account in the MRP only.

 Work instruction: FCS-PC09-WI-SAP-Logistic%20scrap%20(ZJPP04).pdf

BOM explosions and Where-used

 BOM reports that are usefull in FCS are:
 CS11 – Explodes BOM level by level, showing all the levels and what materials are inside
each level
 CS12 – Explodes BOM in multilevel way, showing all levels, mixing levels
 CS13 – Explodes BOM in summarized multilevel way
 ZCS03 – Explodes BOM in multilevel way, showing actual stock
 CS03 – Explodes BOM level by level, showing effective dates and change numbers
 CS15 – Where-used BOM, will show either in single or multilevel all the BOMs where a
semi-finished or a component is used

CS11 – Explodes BOM level by level

 Enter the material number of the finished or semi-finished good,
 Enter the plant code,
 Always use BOM application “PP01”,
 Enter the quantity of finished or semi-finished goods you want to produce or analyze. CS11 will
show how much material is needed for this quantity. If left blank, default to 1000,
 Hit .

CS11 – Explodes BOM level by level
 Level by level
 Quantity needed
 Highlight if a material is a
semi-finished

CS12 – Explodes BOM in multilevel way
 Enter the material number of a finished or semi-

finished good,
 Enter the quantity of finished or semi-finished
goods you want to produce or analyze (the
explosion will show how much material is
needed for this quantity). If left blank, default to
1000,
 Hit .

CS12 – Explodes BOM in multilevel way

 « X » = Assembly (2nd column)
 Quantity needed
 « X » = Phantom (7th column)
 « 50 » = Phantom
 Change number
(for ECM history)

CS13 – Explodes BOM in summarized multilevel way
 Enter the material number of a finished or

semi-finished good,

1000,
 Hit .

CS13 – Explodes BOM in summarized multilevel way

ZCS03 – Explodes BOM in multilevel way with actual stock information
 Enter the material number of a finished or semi-

finished good,
1000,
 Enter Output Device.
 Hit .

ZCS03 – Explodes BOM in multilevel way with actual stock information

CS03 – Explodes BOM level by level with effective dates

 Explosion level by level
 Effective date for each material
 Change numbers used during BOM maintenance

CS15 – Where-used BOM

 Enter a BOP / RM or semi-finished,
 Select « Direct »,
 Click on ,
 Enter a required quantity (if left blank, default
to 1000),
 Enter Plant code,
 Select multi level view (if needed),
 Hit .

CS15 – Where-used BOM
 Shows semi-finished or
finished goods where BOP /
RM or semi-finished entered
in initial screen is used
 Shows BOM level
 Shows the quantity needed

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Scheduling & Pull system

Materials setup in FCS

9th of March 2016 (V6)

Materials setup in FCS V6 4

Hierarchical structure of the data

Plant 1256 (Saint Michel)

FCS storage locations

2. PR10: Production shop

3. OU10: Production shop

The 3 above storage

4. JA10: Jail or Quality

FCS material types

FCS material types

Materials setup in FCS V6 10

Methods to create materials

Manufacturing Engineer: Manufacturing Eng

Purchase Purchasing Product

FCS setup per material type

Source: FCS-PC01-CD- Define Product in ERP

Materials setup in FCS V6 13

MM01: MRP 1 to 4 views

MM01: MRP 1 to 4 views - FCS PC&L setup for materials

Base Unit of Measure

Pl. Deliv. Time

Fixed lot size

 For specific cases, ask helpdesk

MM01: MRP 1 to 4 views - FCS PC&L setup for materials

MRP dep. reqmts

 For specific cases, ask helpdesk

MM01: MRP 1 to 4 views - FCS PC&L setup for materials

Materials setup in FCS V6 18

MM01: Plant data / stor. 1 & 2 views

If you do not want

Materials setup in FCS V6 19

MM01: Plant data / stor. 1 & 2 views

Data coming from

Materials setup in FCS V6 20

MMSC: extend Storage locations for a material

MMSC: extend Storage locations for a material

Materials setup in FCS V6 22

MM01: Classification view

Materials setup in FCS V6 23

MM01: Classification view

Materials setup in FCS V6 24

ZMM_MASTERDATA: report based on Classification view

Materials setup in FCS V6 25

ZMM_MASTERDATA: report based on Classification view

Materials setup in FCS V6 26

BOP example (NON LISA)

Materials setup in FCS V6 27

Group 3: (for participants used to LISA)

Group 5: (for participants used to LISA)

Materials setup in FCS V6 28

ZPP_MATMM: synthetic report of material master data

Materials setup in FCS V6 31

ZPP_MATMM: synthetic report of material master data

Change file to « .xls »