Production planning- Process Industry

Configuration

1. Create Order Type for Process Order using Tcode CORN

Process Order Type: PI01

Enter order category as 40 (process order) and order type as PI01 and save the order type

2. Create Order Type Dependent Parameters using Tcode COR4

Assign Order type PI01 to plant 1000 and save the order dependent parameters
3. Create Production Scheduling Profile using Tcode CORY

In ‘Automatic actions’ on release select all the three functions and save production scheduling
profile
4. Specify Scheduling Parameter using Tcode OPUZ

Create scheduling parameters as per requirement

5. Specify confirmation Parameter for order type PI01
6. Create Control Recipe Destination using Tcode O10C

Control recipe destination is a Process control system, line operator, or group of line operators
that receives

and executes control recipes.

Control Recipe destination: G2

Enter plant, control recipe destination, destination type as 4 (browser based PI sheets) and
address of

operator and save the destination

7. Copy standard characteristics and message categories to the client

Execute adopt predefined characteristics, adopt predefined message categories and adopt
predefined display

variants
8. Create characteristics for process messages and process instructions using Tcode O27C

Enter description, characteristics group as process message characteristics or process

instruction characteristics.

Also enter data type, number of char, number of decimals and unit of measure and save the
characteristic
9. Create Process Massage Destination using Tcode O03C

Process Message destination: PL01

Process massage destination is a User or component to which process messages are sent for
processing.

Enter destination name, Type and destination address and save

10. Create process message categories using Tcode O13C

Process message category: K001

Enter process message category and its description and double click on
‘characteristics/message categories’

and then assign the required characteristics

Now double click on destinations/message categories and enter the process message
destination previously

created

11. Create Process Instruction Category using Tcode O12C

Enter instruction category name, description and process instruction category type
Process instruction category: A001, Process instruction type: 1 (Process parameters)

Double click characteristics/process instruction categories and enter required characteristics and
its values which will get displayed in PI sheet as process parameters

Now create second category K001 with category type as 2 (Process data request) and double
click on characteristics/process instruction categories.
Enter required characteristics as well as predefined characteristics and their values as below and
save the characteristics.

In PI sheet, the process instruction destination has to fill this data and send it to the process
message destination

Master Data

1. Create finished product and its raw materials using Tcode MM01

Finished product: ICE CANDY1 Raw Materials: 7000000116, 7000000117

On ‘work scheduling’ view of finished product, enter production scheduling profile as G001 and
save the material

2. Create finished product BOM using Tcode CS01

Enter the ingredients and quantity in which they are required and save the BOM

3. Create Resource using Tcode CRC1

 Resource: MIXER

4. Create Master Recipe using Tcode C201

In recipe header enter status and usage and the go to ‘Operation’ tab
Enter Phases and operations with required resource and control key also enter the process
instruction destination.
Now save the master recipe and again go to change master recipe using Tcode C202 and then
go to ‘Material’ tab

In production version enter ‘alternative BOM’ and ‘BOM usage’ and select ‘Check’, system will
automatically pic the correct BOM.

Now go to ‘operation’ tab and select phase to which the process instructions are to be assigned
and then

select
For auto goods issue and auto goods receipt select last phase and go to process instructions tab
and assign standard process instructions PROD_5 (auto goods receipt) and CONS_5 (goods
issue), assign CONS_5 two times as there are two ingredients that needed to do goods issue.

Now double click on CONS_5 and assign ingredient number and its base unit of measure to
respective characteristics, repeat same for other ingredient.

Now select Go To- Process management- simulate PI sheet for control recipe destination
System will show the simulation of PI sheet which will be sent to control recipe destination

Phase: 0020

Phase: 0040
Phase: 0080

Now save the control recipe

Business process steps

1. Create Process Order Manual using Tcode COR1

Enter required quantity and release the order

Once release is carried out, the system will give the message

as

As it’s mentioned in production scheduling profile that generate control recipe at the order
release, now save The order.

2. Order confirmation using Tcode COR6N

Enter the order number and phase no. and save the confirmation, similarly do the confirmation of
all the phases.
2. Control recipe monitor using Tcode CO53

Select ‘created/sent’ tab to access generated control recipe

Now select the control recipe and select ‘Send’ to send the recipe to control recipe destination

The system will give message as

3. Maintain PI Sheet using Tcode CO55/CO60

Select the PI sheet and select

Enter the actual values of process parameters that is speed, temperature and viscocity

Enter quantity of finished material to do goods receipt and quantities of raw materials to post
goods issue

Now select ‘complete’ to complete the document and generate process messages

4. Process message monitor using Tcode CO54

Select ‘To Be Sent’ tab to view and edit the process messages

PI_CRST: Process message to change status of control recipe to ‘Executed’

K001: Process message of actual readings of process parameters

PI_PROD: Process message for goods receipt of finished product

PI_CONS: Process message for goods issue of raw materials

Now first to post the goods issue select the PI_CONS message and select
Here enter the storage location in front of characteristic PPPI_STORAGE_LOCATION and save

Now select both PI_CONS messages and select to send the messages at process
message destinations.
Similarly enter storage location in PI_PROD message and send the message to post goods
receipt,

Also check the process parameters and send K001 message to message destination, which is of
SAP user type, this will trigger mail to the address mentioned.

After that send PI_CRST message which will change the status of control recipe to completed.

5. Check the status of control recipe using Tcode CO53

Status of control recipe is ‘Executed’

6. Check good issue and goods receipt documents using Tcode MB51

1. Raw material: 7000000116

2. Raw material: 7000000116

3. Finished product: ICE CANDY1

7. Technical completion of order and order settlement using Tcode KO88

Enter controlling area, order number and settlement period and execute
Resource Classification in Master Recipe
for Planning
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Often, many industries like FMGC, chemical, pharmaceutical, etc use multiple similar
resources to manufacture a product.

E.g. A plant has many mfg bagger, or filling lines with identical capacities. A product is
chronologically said to be manufactured in bagger 2. Alternatively this product also can be
manufactured in bagger 3 or bagger 4 if needed. On shop-floor business cannot determine
the primary resource to be used until shortly before order processing. But in mid to long
term planning, they want to assign a suitable planning resource to the operations
provisionally.
The constraint for long term planning needs to be on planning resource. In short term the
flexibility needs to be given for resource selection based on SKU. This can be mapped in
different ways in SAP.

1. By multiple production Versions with multiple master recipe

This method is most widely used but requires laborious master data maitainance as one
recipe has to be created explicitly for each resource and has to be assigned to one
production version respectively.

2. By manual selection in the Order.

The resource is changed manually on the Order. This change requires a single approval
process if ECM to be used. Production Planners will feel as more work and any change which
needs a Quality Approval in GMP environments will take more time to create and release
the order for production.

3. By Resource Selection through classification.

SAP provides another way of maintaining this alternate resource selection by using resource
classification.

We can use a planning resource as the primary resource and select the alternate resource
through the resource network maintained through work center classification (type 019).
This also works well with ECM and is a good option for Planners as there is no need of Single
Approval from QA personnel.

Create a Characteristic (T-Code CT04)

We can create classifications in ECC for suboperations and secondary resources.

In Additional data tap define Table Name as CRHD and Field Name as ARBPL.

Create Class and assign characteristics to class T Code: CL02

Assign classification in ressource T Code: CRC1 or CRC2

All relevant alternative work centers must contain exactly the same classification and
characteristic value assignment. Work centers with different classes or characteristic values
are ignored.
Assign the classification in master recipe and add alternate resources T Code: C201 or
C202
Create process order COR1 or By MRP Planned order to Process order

On the operations tab, select the operation 10 and click on Resource selection condition
Product can be produced on all 3 lines here you can select the resource accordingly.

Capacity Planning CM25

We can change the resource from this screen by dragging and dropping it to another resource from
the resource section.

Resource classification automatically creates multiple modes in APO PDS or PPM, so it can
be used in PPDS while converting SNP Plan orders to PPDS plan orders. And in DS board we
can schedule the order on required resource.
If we want to use different capacities for planning, but for execution purpose we only want
to use one resource. So from many lines in mid term planning to accommodate constraints,
but for short term we use single resource for production execution.

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

To specify the PI that is to be generated in the process order when control recipe is created for
the control recipe destination. There are steps to be performed such as

1) Define control recipe destinations

2) Assign PI Categories
3) Set process instructions to be generated automatically

Basic steps in PP-PI:

1.(a) In the master recipe, process instructions are attached to the phases.
b) While creating a process order, the control recipe will be created, which will contain the
process instruction.
c) control recipe will be sent to a proper destination and control recipe will be sent back to the
process order and instructions with the data will be available
2) Define profile with default values
3) Assign Material Types
4) Define Recipe Status
5) Define Recipe Usage
6) Define Priority Sequence for auto recipe selection
7) Define Order types
8) Define Order type Dependent parameter
9) Define Number Ranges
10) Process Management
11) Transport Management characteristics
12) Transport Predefined Messages characteristics
13) Define & setup control recipe destination
14) Define process messages characteristics
15) Define & setup message destination
16) Define & setup process message characteristics
17) Define Process Instruction

Before creating PI cockpit you have to do some config.

You have to assgin
Phase 0020 Process Order : 123456
Planned Quantity :
Confirmed Quantity :
Unit of Measurement :
in process instruction category. T/code- O12C
Check APHASE_1, AORD_1, PH_CON - copy required characteristics for phase, process order, planned qty,
confirm qty, unit of measurement and make one Z- process instruction category.
Assign this Z- process instruction category to Master Recipe - select phase and operation then in the top go-to
process management process instruction. - Assign Z-process instruction category here what you have just
created.
Now create process order, before release update charactertistic value like issue item, batch etc , then release
process order, generate control recipe.
Process order, phase, qty will be automatically update in PI cockpit.
MD61 - PIR Creation
MRP Run
MD04 - Stock requirement list.
COR7 - Planned Order To Process Order
COR2 - Contole recipe generation.
COR2 - Release process order.
MB1A - Goods issue (261)
COR6 - Phasewise confirmation
CORK - Header level confirmation
CORR - Collective confirmation.
MB31 - Goods Receipt (101)
Master Data
C201 - Create master recipe - C202/C203
You can create BOM in master recipe itself.
Factory Calendar
Configuring SAP calendar
Define Public Holidays
Define Hoiliday Calendar
Creation of Factory Calendar
Basic Data
Bill of Material
Define Modification Parameters
Define BOM Usages
Define Material Types For BOM Header
Define Item Categories used for Item Data
Define allowed Material Types for BOM Items
Define Order of priority for alternative BOM usages
Work center
Define WorkCenter Category
Define Field Selection for Work Center
Define Task List Usage for Workcenters
Define Parameters for Standard Value Key
Define Standard Value Key
Define Person Responsible for work Centers
Define Move time Matrix
Define Default Work Center
Default Control Keys
Define Capacity Categories
Define Capacity Planners
Define Shift Sequence
Define Worcenter Formulas
Define Work Center Formulas for Costing
Routing
Define Number Ranges for Routings
Define Field Selection
Define Material Type Assignments
Select Automatically (Routing Selection)
Define Task List Usage
Configure Planner Group
Configure Control Keys
Define Reduction Strategy
Define Relevancy to Costing
Define (Standard) Trigger Point Usage
Define Automatic Selection of Routings
Production Planning
Demand Management
Define number ranges for planned independent requirements
Configuring Requirement Types and Requiremtent Classes
Define Strategy
Define Strategy Group
Define version numbers
Maintain consumption mode and period of adjustment
CRP Define layout keys
Define layout
Define profile for capacity planning table
Define Overall profile
Material Requirement Planning Plant Parameters
Carry Out Overall Maintenance of Plant Parameters
Scheduling Parameters for Purchasing
Number Range for Planned orders
Number Range for Puchase Requisitions
Define MRP Controllers
Define Missing Parts MRP Controller
Define Special Procurement Type
Maintain Planning Calendar
Define MRP Areas
Define Scope of Planning for Total Planning
Define Planning Horizon
Activate BOM Expllosion characteristics
Define Planning Time Fence and Roll Forward Period
Define Floats (Scheduling Margin Key)
Define Parallel processing for MRP
Define Receipt days Supply
Parameters for Determining the Basic Dates
Define scheduling parameters for planned orders
Define availability stock in Transfer/Blocked stock/Restricted stock
Define External Procurement
Define BOM Explosion Control
Define BOM Explosion for Sales Orders
Define BOM and Routing Selection
Activate MRP and Set Up Planning File
Define Planning File Entries for Goods Movements
Convert Planning File Entries for MRP Areas
Shop Floor Control Master Data
Define Order Types
Define order type-dependent parameters
Production Status Profile
Define number ranges for orders
Define number ranges for confirmations
Define number ranges for reservations
Define production scheduler
Define production scheduling profile
Define Confirmation Parameters
Define Time for Confirmation Processes
Define Reasons for Variances
Define single screen entry
Define Field Selection for Confirmation
Define Reduction Strategies
Define Print Control
Batch Status Mangement
Batch Search Strategy to Production
Activate Batch Management
Availability Check
Define Checking Group
Define Checking Rule
Define Scope of Check
Define Checking Control
Checking Rule for Back order Processing
Scheduling
Specify Scheduling Type
Define Scheduling Parameters for Planned Orders
Define Scheduling Parameters for Production Orders

What is SAP Engineering Change Management?

SAP Engineering Change Management is a central logistics function that can be

used to change various aspects of production basic data (for example, BOMs, task
lists, materials, and documents) with history (with date effectively) or depending
on specific conditions (with parameter effectively).

The following is a sample basic SAP Engineering Change Management Setup.

These are the basic IMG settings in order to use the Logistics Engineering Change
Management features.

The x refers to a tick.

Firstly setup the control data in OS54.

Revision sections

Fields Name :-

Revision level active x

Ext. revision level x
Higher revision level x

Object Management Record sections

Fields Name :-

Object maintenance x
Assign alternative date x

Override value/assignment date sections

Fields Name :-
Only with leading change mst. x

Setting the Revision level active is to activate the ECM for material master. If you
do not want the engineering change management for materials, remove the tick.

With a tick in "Higher revision level", the new revision level has to be always
higher than the old revision.

Secondly, setup the external number range in OS53.

If you use the internal number range, then remove the external number range.

Third, define the status for the change master records in transaction SM30 -
V_T419S.

Change No. Chg Date Chg Dist. Lock Description

Status Poss
1 x x '' Active
2 '' '' '' Inactive
3 '' '' x Locked

Fourth, define modification parameters for the BOM in OS27.

Fields :-

BOM Validity Maint. x

EC Management Active x
History Requirement ''
Unit Piece PC

The rest of the fields are blank.

If the History Requirement is tick, every time during creation of the BOM, SAP
will prompt you for an ECN number as is compulsory.

Lastly, define fields selection for routing in OP5A.

PP task lists: initial screen -> Change number -> Transaction code -> Tick Req.

Setting the Transaction code fields Required indicate that you have make the ECN
number compulsory when changing the routing.

Finally, test it by making changes to the Material Master, BOM and Routing.

What are the activities involve in Engineering Change Management?

The Engineering Change Management is for creating creates simple change master
records and engineering change requests and processes them further. It is for SAP
Users to prepares the change to the production order or the purchase requisition. In
that the user identifies the requests or purchase requisitions affected by a change.
In addition, the user carries out the reporting of the Engineering Change
Management.

Transaction Activities in Engineering Change Management

Change number

Transaction Activity

CC01 - Create change number

CC02 - Change change number

CC03 - Display change number

Object management record

CC22 - Change object management record

CC23 - Display object management record

Engineering Change Management for production orders

COCM - Change order process u2013 source item

Revision level

CC11 - Create revision level for material

CC12 - Change revision level for material

CC13 - Display revision level for material

CC15 - Change revision level for document

CC16 - Display revision level for document

Reporting
CS80 - Material BOM change document

CV80 - Document BOM change document

CS82 - Order BOM change document

CC05 - Change overview

CC60 - Change hierarchy

CJ00 - Find digital signatures

Configuration Management

CMWO - Configuration Management workbench

BOM related tables :-

STKO --- BOM - header

STPO --- BOM - item

STAS --- BOMs - Item Selection

STPN --- BOMs - follow-up control

STPU --- BOM - sub-item

STZU --- Permanent BOM data

PLMZ --- Allocation of BOM - items to operations

MAST --- Material to BOM link

KDST --- Sales order to BOM link

PLPLAN_PARAM --- BOM-dependent planning parameter

SNUM --- BOM explosion number

T415S --- BOM status

T415T --- BOM Status Texts

T416 --- BOM Usage - Item Statuses

T416T --- BOM Usage Texts

T618EM --- BOM of CAP material components

TCS09 --- BOM Control Depending on Category and Usage

TCS11 --- BOM Objects

TCS15 --- BOMs with History Requirement

TCS17 --- BOMs with History Requirement

TCS19 --- BOM Item Object Types

TCS21 --- BOM Item Object Types: internal > external

TCS22 --- BOM Item Object Types: external > internal

TCS31 --- BOM Field Selection - Usage (T416)

TCS32 --- BOM to Plant Allocation - Field Selection

TCS33 --- BOM Field Selection (SAP)

TCS34 --- BOM Field Selection - Control Data (TCS03)

Work center
CRHH - Work center hierarchy
CRHS - Hierarchy structure
CRHD - Work center header
CRTX - Text for the Work Center or Production Resource/Tool
CRCO - Assignment of Work Center to Cost Center
KAKO - Capacity Header Segment
CRCA - Work Center Capacity Allocation
TC24 - Person responsible for the work center

Routings/operations
MAPL - Allocation of task lists to materials
PLAS - Task list - selection of operations/activities
PLFH - Task list - production resources/tools
PLFL - Task list - sequences
PLKO - Task list - header
PLKZ - Task list: main header
PLPH - Phases / suboperations
PLPO - Task list operation / activity
PLPR - Log collector for task lists
PLMZ - Allocation of BOM - items to operations

Bill of material
STKO - BOM - header
STPO - BOM - item
STAS - BOMs - Item Selection
STPN - BOMs - follow-up control
STPU - BOM - sub-item
STZU - Permanent BOM data
PLMZ - Allocation of BOM - items to operations
MAST - Material to BOM link
KDST - Sales order to BOM link

Production orders
AUFK - Production order headers
AFIH - Maintenance order header
AUFM - Goods movement for prod. order
AFKO - Order header data PP orders
AFPO - Order item
RESB - Order componenten
AFVC - Order operations
AFVV - Quantities/dates/values in the operation
AFVU - User fields of the operation
AFFL - Work order sequence
AFFH - PRT assignment data for the work order(routing)
JSTO - Status profile
JEST - Object status
AFRU - Order completion confirmations

PRT’s production orders

AFFH - PRT assignment data for the work order
CRVD_A - Link of PRT to Document
DRAW - Document Info Record
TDWA - Document Types
TDWD - Data Carrier/Network Nodes
TDWE - Data Carrier Type

Planned orders
PLAF - Planned orders

KANBAN
PKPS - Kanban identification, control cycle
PKHD - Kanban control cycle (header data)
PKER - Error log for Kanban containers
Reservations
RESB - Material reservations
RKPF - Header

Capacity planning
KBKO - Header record for capacity requirements
KBED - Capacity requirements records
KBEZ - Add. data for table KBED (for indiv. capacities/splits)

Planned independent requirements

PBIM - Independent requirements for material
PBED - Independent requirement data
PBHI - Independent requirement history
PBIV - Independent requirement index
PBIC - Independent requirement index for customer req.

Go to tcode SPRO

These are the configuration settings available for BOM. Depending on your
Business configuration i.e. Business blue print, you have to use these settings
accordingly.

1.1. Bill of Material

1.1.1. Control Data for Bill of material

1.1.1.1. Define modification parameters (OS27)

1.1.1.2. Default Values (OS28)

1.1.2. General Data

1.1.2.1. BOM Usage

1.1.2.1.1. Define BOM Usage (OS20)

1.1.2.1.2. Define Default Values for the Item Status

1.1.2.1.3. Define copy default for Item Status

1.1.2.2. Define Material types allowed for BOM Header (OS24)

1.1.2.3. Define BOM Status

1.1.3. Item Data

1.1.3.1. Define Item categories

1.1.3.2. Define Allowed Material Types for BOM Items (OS14)

1.1.3.3. Define variable-Size item Formulas

1.1.3.4. Define Spare Part Indicator

1.1.3.5. Define Material Provision Indicators

1.1.3.6. Item Data From Related Application Areas

1.1.3.6.1. Define Distribution Keys

1.1.3.6.2. Define Relevancy To Costing

1.1.4. Alternative Determination

1.1.4.1. Define Order of Priority for BOM Usag

Planning with Final Assembly (40)

Purpose
This strategy is probably the most widely used make-to-stock strategy. It makes sense to use this
planning strategy if you can forecast production quantities for the final product.

Planned independent requirements are consumed by incoming sales orders so that the master plan is
always adjusted to suit the current requirements situation. This means that the important feature of
this planning strategy is that you can react quickly to customers’ requirements. The smoothing of the
master plan is less important.

Prerequisites
You must maintain the following master data for the finished product in the material master:

 Strategy group 40 on the MRP screen.

 Consumption parameters (Consumption mode, Bwd consumption, Fwd consumption) to allow
consumption of independent requirements. If no consumption parameters are maintained in
the material master, the system uses default values are taken from the MRP group.

To control consumption, you maintain a consumption mode as well as a consumption period.

For more information, see Consumption Strategies and Logic.
  Item category group (for example, NORM) on the Sales Organization Data screen.

Process Flow

For a detailed example of the entire process, see Sample Scenario: Strategy 40.

1. Planned independent requirements are entered at finished product level and trigger the
procurement and production of the necessary assemblies and components before receipt of
the sales orders.

It is possible to use information from the sales forecast, the Sales Information System, or
other planning tools to plan production quantities.

2. As soon as the sales order is received, it consumes the planned independent requirements.
You can then compare the planned independent requirements situation with the actual
customer requirements situation.
3. An accurate availability check is performed according to ATP (available to promise) logic
during sales order processing. The system checks whether sufficient planned independent
requirements have been planned to cover the sales order.
4. Requirements from the sales orders are passed on to production and can lead to changes
made to procurement if the requirements from the sales orders exceed the planned
independent requirement quantities. If there is insufficient coverage of components (the sales
order quantities exceed the planned independent requirement quantities), the sales orders
cannot be confirmed. The system therefore automatically adjusts the master plan. For more
information see Coping with Insufficient Coverage of Components. Planned independent
requirement quantities that are left unconsumed increase the warehouse stock of the finished
product.

Other Areas
Availability Check
Unlike other planning strategies, strategy 40 does not require the material master MRP II Availability
check to contain a specific value. This field has no major impact on the strategy 40 planning process.
You can use the S/D checking rule either with or without replenishment lead times. From the sales
order choose Edit  Item availability  Goto  Scope of check. See Availability Check.

Statistics in Demand Management

For Planning Strategy 40, the system displays only order quantities that have consumed independent
requirements. Quantities that are in excess of this amount are not displayed. For example, suppose
the following situation:

 Stock Available: 100 pieces

 Planned Independent requirements: 50 pieces
 Two sales orders: 50 pieces in each order (the orders’ dates are close enough that they can
consume the planned independent requirements of 50 pieces)

Confirm the creation of the sales orders, and the consumption of the planned independent
requirements in the Stock Requirements List.

Choose Logistics  Production  Master Planning  Demand

Management  Evaluations  Display total requirements. The Total Requirements List shows only
those sales orders that have reduced the independent requirements. Orders are allocated to
independent requirements on a first come, first served basis. When independent requirements are
fully consumed by current orders, they cannot be further reduced by new orders. New orders are not
displayed on the Total Requirements List. The system performs this process dynamically, based on a
calculation. The allocation does not display on the database.

As a result, the statistics in Demand Management may not display all sales figures over a planning
period. In the example, only the 50 pieces of the first sales order display in the Total Requirements
List, even though more were sold. Other functions, such as LIS or SIS, can be used to display those
extra orders.