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BPC SAP ERP CH 06 Production 1e FInal
BPC SAP ERP CH 06 Production 1e FInal
BPC SAP ERP CH 06 Production 1e FInal
Magal, Boykin, Goodrich, and Prabhakar | Business Processes Configuration with SAP ERP | © Epistemy Press 2017
The Production Process
Planned
Planned Production
Production Goods
Goods Order
Order Goods
Goods Order
Order
order
order order
order issue
issue confirmation
confirmation receipt
receipt settlement
settlement
Magal, Boykin, Goodrich, and Prabhakar | Business Processes Configuration with SAP ERP | © Epistemy Press 2017
Planned Order
Request production
Planned order data
What material
How many
When
Magal, Boykin, Goodrich, and Prabhakar | Business Processes Configuration with SAP ERP | © Epistemy Press 2017
Production Order
Magal, Boykin, Goodrich, and Prabhakar | Business Processes Configuration with SAP ERP | © Epistemy Press 2017
Production Order Release
Magal, Boykin, Goodrich, and Prabhakar | Business Processes Configuration with SAP ERP | © Epistemy Press 2017
Goods Issue
Magal, Boykin, Goodrich, and Prabhakar | Business Processes Configuration with SAP ERP | © Epistemy Press 2017
Confirmations
Magal, Boykin, Goodrich, and Prabhakar | Business Processes Configuration with SAP ERP | © Epistemy Press 2017
Goods Receipt
Impact
Material, FI, CO documents
Material master update (quantity and value)
Production order update (quantity, date, costing)
Magal, Boykin, Goodrich, and Prabhakar | Business Processes Configuration with SAP ERP | © Epistemy Press 2017
Periodic Processing
Overhead calculation
Work in progress determination
Settlement
10
Magal, Boykin, Goodrich, and Prabhakar | Business Processes Configuration with SAP ERP | © Epistemy Press 2017
Overhead Calculation
Indirect costs
Supervisor, manager, other salaries
Utilities
11
Magal, Boykin, Goodrich, and Prabhakar | Business Processes Configuration with SAP ERP | © Epistemy Press 2017
Work-in-Progress Determination
Periodically the value of what is in the production process is calculated and posted to the general ledger
Not essential
For short production processes
Value of materials is not high
GBI
Essential
When value of materials is high
Production takes weeks, months, or years
Aircraft production, construction.
12
Magal, Boykin, Goodrich, and Prabhakar | Business Processes Configuration with SAP ERP | © Epistemy Press 2017
Settlement
13
Magal, Boykin, Goodrich, and Prabhakar | Business Processes Configuration with SAP ERP | © Epistemy Press 2017
Agenda
Magal, Boykin, Goodrich, and Prabhakar | Business Processes Configuration with SAP ERP | © Epistemy Press 2017
Enterprise Structure
Plant
Valuation area
Storage location
Controlling area
Cost center standard hierarchy
Work center / work center location
Magal, Boykin, Goodrich, and Prabhakar | Business Processes Configuration with SAP ERP | © Epistemy Press 2017
Work Center Location
Magal, Boykin, Goodrich, and Prabhakar | Business Processes Configuration with SAP ERP | © Epistemy Press 2017
Agenda
Magal, Boykin, Goodrich, and Prabhakar | Business Processes Configuration with SAP ERP | © Epistemy Press 2017
Parameters
Magal, Boykin, Goodrich, and Prabhakar | Business Processes Configuration with SAP ERP | © Epistemy Press 2017
Plant Parameters – Number Ranges
Planned orders
Reservations / dependent requirements
Purchase requisitions
Magal, Boykin, Goodrich, and Prabhakar | Business Processes Configuration with SAP ERP | © Epistemy Press 2017
Production Scheduling Profile
Plant Specific
A plant can have multiple profiles
Automatic actions
Release on create
Schedule on release
Goods receipt on confirmation
Tasks
Material commitment
Capacity commitment
Scheduling options
Magal, Boykin, Goodrich, and Prabhakar | Business Processes Configuration with SAP ERP | © Epistemy Press 2017
Production Scheduler
Magal, Boykin, Goodrich, and Prabhakar | Business Processes Configuration with SAP ERP | © Epistemy Press 2017
Production Scheduling Profile - assignment
Assign profile to
Scheduler
Material Master – Work Scheduling view
Material master
to
s ig
d
ne
n
master ed
sig
to
As
Profile inherited from scheduler Material Master
Magal, Boykin, Goodrich, and Prabhakar | Business Processes Configuration with SAP ERP | © Epistemy Press 2017
Plant Parameters – MRP Controllers
Magal, Boykin, Goodrich, and Prabhakar | Business Processes Configuration with SAP ERP | © Epistemy Press 2017
Order Type
Order types
Order type parameters
Order category
Settlement profile
Magal, Boykin, Goodrich, and Prabhakar | Business Processes Configuration with SAP ERP | © Epistemy Press 2017
Order Type Parameters
Magal, Boykin, Goodrich, and Prabhakar | Business Processes Configuration with SAP ERP | © Epistemy Press 2017
Order Type Parameters – Planning (Master Data)
Production version
Automatic vs. manual selection
Routing
Routing type (application)
Mandatory vs. optional
Automatic vs. manual
Bill of materials
BOM usage
Magal, Boykin, Goodrich, and Prabhakar | Business Processes Configuration with SAP ERP | © Epistemy Press 2017
Order Type Parameters – Planning (General)
Assignment
MRP controller
Production scheduler
Purchase requisitions / material
reservations
Release
Collective conversion
Quality inspection
Inspection type
Magal, Boykin, Goodrich, and Prabhakar | Business Processes Configuration with SAP ERP | © Epistemy Press 2017
Order Type Parameters – Cost Accounting
Magal, Boykin, Goodrich, and Prabhakar | Business Processes Configuration with SAP ERP | © Epistemy Press 2017
Conversion of Planned Orders
Magal, Boykin, Goodrich, and Prabhakar | Business Processes Configuration with SAP ERP | © Epistemy Press 2017
Floats / Scheduling Margin Key
Configuration Steps Demo – Scheduling Margin Key Configuration Steps Demo – Plant Parameters
Navigation: SAP Customizing Implementation Guide ► Production ► Shop Floor Navigation: SAP Customizing Implementation Guide ► Production ► Materials
Control ► Operations ► Operations ► Scheduling ► Define Scheduling Margin Requirements Planning ► Plant Parameters ► Carry Out Overall Maintenance of
Key Plant Parameters
Magal, Boykin, Goodrich, and Prabhakar | Business Processes Configuration with SAP ERP | © Epistemy Press 2017
Floats / Scheduling Margin Key
Release period
9 days
Float before Production Float after
production time production
3 days 7 days 5 days
Magal, Boykin, Goodrich, and Prabhakar | Business Processes Configuration with SAP ERP | © Epistemy Press 2017
BOM selection
BOM selection
Selection ID
Priority
Usage
Magal, Boykin, Goodrich, and Prabhakar | Business Processes Configuration with SAP ERP | © Epistemy Press 2017
Routing selection
Routing selection
Selection ID
Priority
Type
Usage
Status
Magal, Boykin, Goodrich, and Prabhakar | Business Processes Configuration with SAP ERP | © Epistemy Press 2017
Availability Check
Checking group
Checking rule
Scope of check
Checking control
Magal, Boykin, Goodrich, and Prabhakar | Business Processes Configuration with SAP ERP | © Epistemy Press 2017
Availability Check – Checking Group (Review)
Requirements Requirements
Define checking group Group for sales orders for deliveries
Similar to fulfillment
Daily requirements for planning (01)
Individual requirements for planning (02)
Magal, Boykin, Goodrich, and Prabhakar | Business Processes Configuration with SAP ERP | © Epistemy Press 2017
Availability Check – Checking Rule
Magal, Boykin, Goodrich, and Prabhakar | Business Processes Configuration with SAP ERP | © Epistemy Press 2017
Availability Check Rule
Magal, Boykin, Goodrich, and Prabhakar | Business Processes Configuration with SAP ERP | © Epistemy Press 2017
Availability Check – Scope of Check
Magal, Boykin, Goodrich, and Prabhakar | Business Processes Configuration with SAP ERP | © Epistemy Press 2017
Availability Check – Check without RLT
Magal, Boykin, Goodrich, and Prabhakar | Business Processes Configuration with SAP ERP | © Epistemy Press 2017
Availability Check: Relationships
Scope of check
Example: PP + 02
Magal, Boykin, Goodrich, and Prabhakar | Business Processes Configuration with SAP ERP | © Epistemy Press 2017
Availability Check – Checking Control
Order control
When is the check automatically executed?
On order create
On order release
Configured for combination of
Plant
Order type
Process step
Create
Release
Magal, Boykin, Goodrich, and Prabhakar | Business Processes Configuration with SAP ERP | © Epistemy Press 2017
Scheduling Parameters
Scheduling control
Backward vs. forward
Magal, Boykin, Goodrich, and Prabhakar | Business Processes Configuration with SAP ERP | © Epistemy Press 2017
Activate Requirements Planning
Magal, Boykin, Goodrich, and Prabhakar | Business Processes Configuration with SAP ERP | © Epistemy Press 2017
Confirmation parameters
Defined for
Plant + Order type
Process control
Tasks
Automatic GR
Backflush
Actual costs
Options
Immediately
Later (via program)
Later (via background job)
Magal, Boykin, Goodrich, and Prabhakar | Business Processes Configuration with SAP ERP | © Epistemy Press 2017
Confirmation parameters
Checks
Operations sequence
Valid for operations confirmations
Do not check
Check and warn
Check and error
Tolerances (under/over delivery)
Do not check
Warn
Error
Magal, Boykin, Goodrich, and Prabhakar | Business Processes Configuration with SAP ERP | © Epistemy Press 2017
Confirmation parameters
Confirmation type
Partial
Final
Open reservations
Magal, Boykin, Goodrich, and Prabhakar | Business Processes Configuration with SAP ERP | © Epistemy Press 2017
Work center control keys
Magal, Boykin, Goodrich, and Prabhakar | Business Processes Configuration with SAP ERP | © Epistemy Press 2017
Work center control keys
Magal, Boykin, Goodrich, and Prabhakar | Business Processes Configuration with SAP ERP | © Epistemy Press 2017
Work center control keys
Routing
Assigned to
Work centers
Control key from WC are copied to routings
Reference indicator: data in routing cannot be
changed
Routings
Work Center
Magal, Boykin, Goodrich, and Prabhakar | Business Processes Configuration with SAP ERP | © Epistemy Press 2017
Work Center Category
Assigned to
Magal, Boykin, Goodrich, and Prabhakar | Business Processes Configuration with SAP ERP | © Epistemy Press 2017
Which steps have financial accounting (FI) or management
accounting (CO) impact?
What steps have an FI / CO impact?
CO FI CO CO FI CO FI CO
Need account determination (FI) for: Planned
Planned
order
order
Production
Production
order
order
Goods
Goods
issue
issue
Order
Order
confirmation
confirmation
Goods
Goods
receipt
receipt
Order
Order
settlement
settlement
Goods issue
Goods receipt
Price difference(s)
Need rules for controlling impact
Planned costs (Production Order)
Actual costs
Material costs (GI)
Labor costs (Confirmation)
Settlement
Goods receipt
Variance
Magal, Boykin, Goodrich, and Prabhakar | Business Processes Configuration with SAP ERP | © Epistemy Press 2017
Costing Parameters – Costing Type
Magal, Boykin, Goodrich, and Prabhakar | Business Processes Configuration with SAP ERP | © Epistemy Press 2017
Costing parameters – Valuation Variants
Magal, Boykin, Goodrich, and Prabhakar | Business Processes Configuration with SAP ERP | © Epistemy Press 2017
Costing parameters - Valuation variant 006 (Planned)
Magal, Boykin, Goodrich, and Prabhakar | Business Processes Configuration with SAP ERP | © Epistemy Press 2017
Costing parameters – Costing Variant
Combination of
Costing type
Valuation variant
Valuation
Costing type
variant
Costing variant
Magal, Boykin, Goodrich, and Prabhakar | Business Processes Configuration with SAP ERP | © Epistemy Press 2017
Production Order
Magal, Boykin, Goodrich, and Prabhakar | Business Processes Configuration with SAP ERP | © Epistemy Press 2017
Figure 6-37
Magal, Boykin, Goodrich, and Prabhakar | Business Processes Configuration with SAP ERP | © Epistemy Press 2017
Automatic Account Determination GI – Offsetting Entry
Modification Description
VAX GI for sales order
BSA Initial entry of stock
VBR GI for consumption
AUF GR for orders
Magal, Boykin, Goodrich, and Prabhakar | Business Processes Configuration with SAP ERP | © Epistemy Press 2017
Goods issue
Magal, Boykin, Goodrich, and Prabhakar | Business Processes Configuration with SAP ERP | © Epistemy Press 2017
Confirmation
Allocation of cost
Cost center associated From: Cost center associated with work center
with the work center
To: production order
$ 260 Activity type: labor
Activity price: $60 per hour
Time recorded at confirmation: 26 minutes per bike
Planned Actual Target Variance
(estimate) (debit) (credit)
Material $5,800 $6,000
(10 x $580) (10 x $600)
Labor $250 $260
(10 X 25 X $1) (10 X 26 X $1)
Total $6050
Magal, Boykin, Goodrich, and Prabhakar | Business Processes Configuration with SAP ERP | © Epistemy Press 2017
Valuation of Goods Receipt
Magal, Boykin, Goodrich, and Prabhakar | Business Processes Configuration with SAP ERP | © Epistemy Press 2017
Valuation of Goods Receipt
Magal, Boykin, Goodrich, and Prabhakar | Business Processes Configuration with SAP ERP | © Epistemy Press 2017
Automatic Account Determination GR – Inventory Posting
Magal, Boykin, Goodrich, and Prabhakar | Business Processes Configuration with SAP ERP | © Epistemy Press 2017
Automatic Account Determination GR – Offsetting Entry
Modification Description
VAX GI for sales order
BSA Initial entry of stock
VBR GI for consumption
AUF GR for orders
Magal, Boykin, Goodrich, and Prabhakar | Business Processes Configuration with SAP ERP | © Epistemy Press 2017
Goods Receipt
Magal, Boykin, Goodrich, and Prabhakar | Business Processes Configuration with SAP ERP | © Epistemy Press 2017
Automatic Account Determination – Production Variance
Magal, Boykin, Goodrich, and Prabhakar | Business Processes Configuration with SAP ERP | © Epistemy Press 2017
Settlement of Variance
Production Variance Mfg. Output Settlement G/L account determined by automatic account
$ 210 $ 210
determination
GBB
PRD: Production variance account
PRD
GBB: offsetting entry = manufacturing output settlement
(plant activity account)
Magal, Boykin, Goodrich, and Prabhakar | Business Processes Configuration with SAP ERP | © Epistemy Press 2017
Cost Calculations
Total labor time = time per base quantity * quantity produced / base quantity
= 10 * 60 / 12
= labor time * operation quantity / base quantity
Formula key = parameter1 * parameter 2 / parameter 3
SAP007 (labor) = SAP_03 * SAP_09 / SAP_08
SAP006 (machine) = SAP_02 * SAP_09 / SAP_08
Magal, Boykin, Goodrich, and Prabhakar | Business Processes Configuration with SAP ERP | © Epistemy Press 2017
Standard Value Keys
Parameters
Setup
Machine
Labor
Teardown
etc.
Magal, Boykin, Goodrich, and Prabhakar | Business Processes Configuration with SAP ERP | © Epistemy Press 2017
Formula Keys
Formula key
For specific calculations
Formula
Parameters
Magal, Boykin, Goodrich, and Prabhakar | Business Processes Configuration with SAP ERP | © Epistemy Press 2017
Agenda
Magal, Boykin, Goodrich, and Prabhakar | Business Processes Configuration with SAP ERP | © Epistemy Press 2017
Master Data
Material master
Bill of materials
Activity type
Activity price
Capacity
Work center
Routing
Magal, Boykin, Goodrich, and Prabhakar | Business Processes Configuration with SAP ERP | © Epistemy Press 2017
Material Master
Magal, Boykin, Goodrich, and Prabhakar | Business Processes Configuration with SAP ERP | © Epistemy Press 2017
Material Master
Magal, Boykin, Goodrich, and Prabhakar | Business Processes Configuration with SAP ERP | © Epistemy Press 2017
Material Master – MRP Views
Parameters
MRP controller
Scheduling margin key
Availability check
Additional data
In house production time
Goods receipt processing time
Magal, Boykin, Goodrich, and Prabhakar | Business Processes Configuration with SAP ERP | © Epistemy Press 2017
Material Master – Work Scheduling View
Production supervisor
(scheduler)
Production scheduling profile
Times
Lot size dependent or
Lot size independent
Lot size dependent
Setup
Processing
Interoperation
Lot size independent
In house production time
Magal, Boykin, Goodrich, and Prabhakar | Business Processes Configuration with SAP ERP | © Epistemy Press 2017
Bill of Materials (BOM)
List of components to produce the product A component can have its own BOM to creates a
Material BOM – the most common form of a BOM multi-level BOM
Order BOM – used in make-to-order environment when
the customer can customize the product
BOMs are used in
Material planning
Used to determine: Production
Net requirements for all materials Procurement
Order quantities Product costing
Available to promise dates
Magal, Boykin, Goodrich, and Prabhakar | Business Processes Configuration with SAP ERP | © Epistemy Press 2017
Bill of Materials (BOM): Deluxe Touring Bike (Black)
DXTR1000
Deluxe
Touring Bike
(Black)
TRWH 1000
LWSH1000 BOLT1000
TRTR 1000 TRTB 1000 Touring HXNT1000
Lock washer Socket head
Touring tire Touring tube aluminum Hex nut
(2) bolt
wheel
Magal, Boykin, Goodrich, and Prabhakar | Business Processes Configuration with SAP ERP | © Epistemy Press 2017
Bill of Materials
Magal, Boykin, Goodrich, and Prabhakar | Business Processes Configuration with SAP ERP | © Epistemy Press 2017
Bill of Materials
Item Category
Stock item
Non-stock item
Variable sized item
Document item
Quantity
Assembly
Semifinished good
Has its own BOM
Magal, Boykin, Goodrich, and Prabhakar | Business Processes Configuration with SAP ERP | © Epistemy Press 2017
Direct Allocation (Review)
Posting data
Sending cost center
Receiver (controlling object)
Activity type
Quantity of activity
Magal, Boykin, Goodrich, and Prabhakar | Business Processes Configuration with SAP ERP | © Epistemy Press 2017
Internal Activity Allocation Example (Review)
Magal, Boykin, Goodrich, and Prabhakar | Business Processes Configuration with SAP ERP | © Epistemy Press 2017
Confirmation (Review)
Total $830
Magal, Boykin, Goodrich, and Prabhakar | Business Processes Configuration with SAP ERP | © Epistemy Press 2017
Activity Type (Review)
Magal, Boykin, Goodrich, and Prabhakar | Business Processes Configuration with SAP ERP | © Epistemy Press 2017
Activity Prices (Review)
Parameters
Plan activity (quantity)
Unit of measure (hours)
Activity price
Fixed
Variable (per unit)
Price unit
Per 1, 100, dozen
Cost element for allocation
Magal, Boykin, Goodrich, and Prabhakar | Business Processes Configuration with SAP ERP | © Epistemy Press 2017
Capacity
Parameters
Category
Factory calendar
Default = plant calendar
Versions
Active vs other
Base unit of measure
Definition
Start, end, breaks
Capacity utilization rate
Actual = theoretical * rate
Number of individual capacity
Number of machines, people
Total capacity = operating time * number of individual
capacities * utilization rate
Magal, Boykin, Goodrich, and Prabhakar | Business Processes Configuration with SAP ERP | © Epistemy Press 2017
Work Center – Basic Data
Assigned to a plant
Work center category
What data are needed
Assigned to applications
Location
Person responsible
Usage (task list)
Magal, Boykin, Goodrich, and Prabhakar | Business Processes Configuration with SAP ERP | © Epistemy Press 2017
Work Center – Basic Data
Magal, Boykin, Goodrich, and Prabhakar | Business Processes Configuration with SAP ERP | © Epistemy Press 2017
Work Center – Default Values
Previously discussed
WC control keys are copied to routing
Ref. Ind = key in routing cannot be changed
Magal, Boykin, Goodrich, and Prabhakar | Business Processes Configuration with SAP ERP | © Epistemy Press 2017
Work Center - Scheduling
Scheduling basis
Capacity category
Capacity
Execution time
Formula keys
Magal, Boykin, Goodrich, and Prabhakar | Business Processes Configuration with SAP ERP | © Epistemy Press 2017
Work Center - Costing
Controlling data
Controlling area
Cost center
Activities
Formula key to calculate time
Activity type to determine rate
Magal, Boykin, Goodrich, and Prabhakar | Business Processes Configuration with SAP ERP | © Epistemy Press 2017
Product Routing - Operations
Magal, Boykin, Goodrich, and Prabhakar | Business Processes Configuration with SAP ERP | © Epistemy Press 2017
Agenda
Magal, Boykin, Goodrich, and Prabhakar | Business Processes Configuration with SAP ERP | © Epistemy Press 2017
Testing – Scenarios
Magal, Boykin, Goodrich, and Prabhakar | Business Processes Configuration with SAP ERP | © Epistemy Press 2017
Agenda
Magal, Boykin, Goodrich, and Prabhakar | Business Processes Configuration with SAP ERP | © Epistemy Press 2017