/tema17 by rapha Torres

!""#$%&'()*()'#+,&-#-( !""#$%&'()*(.+/%0,1&/$()'#,01&/$(2(.+/,#--(3+%#+( 4#$#+56(7$8/+951&/$( In this unit we will use a process order to perform production execution activities. The business scenario is:

:0"#+;<#9(

•

Produces fertilizer for the landscape and gardening industry.

•

The fertilizer is built to stock.

•

Uses process orders to manufacture the fertilizer.

TERP10

21-1

TERP10

21-2

!"#$%&'#'( )*&+,(-$./0%+&.*(-12**&*3(4(!"#%0+&.*( ( 5.6&%,(72'+#$(82+2(9.$(-$.%#''(:*/0'+$&#'( At the conclusion of these exercises, you will be able to: • Display a master recipe

In your plant 1100 in Berlin, liquid fertilizer by SuperChem is only ordered by Specialty Garden Products whose requirements are unpredictable. This fertilizer needs to be used within a limited period of time after it is produced, for it to be effective. Since the liquid fertilizer has a very limited requirement, is expensive to carry, and tends to lose its potency over time, SuperChem only produces the product only after the customer orders it. The make-to-order planning strategy in the R/3 System is used to support the planning of the special formulation liquid fertilizer.

1-1

Display master recipe T-RC9##. 1-1-1

Which short description has been maintained for the recipe? ______________________________________________________

1-1-2

You are in the recipe’s operation overview. Here, an overview of the individual steps in the manufacturing process is displayed.

1-1-3

Display the material list for the recipe. The recipe is used to describe the production of which product? ______________________________________________________ Which material components are required to manufacture this product? ______________________________________________________ ______________________________________________________ ______________________________________________________

TERP10

21-3

TERP10

21-4

!"#$%&'#'( )*&+,(-$./0%+&.*(-12**&*3(4(!"#%0+&.*( ( 5.6&%,(721#'(8$/#$(2*/(92+#$&21(:#;0&$#<#*+'(-12**&*3( At the conclusion of these exercises, you will be able to: • Create a sales order • Perform material requirements planning in make-to-order production • Describe the special aspects of material requirements planning in make-to-order production • Describe the key material master data settings that support a make-toorder environment Specialty Garden Products orders 10,000 liters of the special liquid fertilizer. You will create a sales order and carry out material requirements planning.

2-1

Create a sales order for your material T-FF9##. 2-1-1

Create the sales order for order type !"#$%&'()'*)#+*),*-#using the following organizational units: Sales organization: 1000 Distribution channel: 10 Division: 00 The sold-to-party, that is, the customer placing the sales order, is the company Specialty Garden Products. The customer record is managed and identified in the system under sold-to-party number F-1001 at SuperChem. Enter purchase order number 12389-## to identify the customer’s order. The required delivery date should be made two weeks from today. The order quantity for the requested product T-FF9## is 10,000 liters. Enter data as required when creating the sales order and save the order. Write down the order number: _______________________________________________________ Exit sales order processing.

TERP10

21-5

2-2

Display the stock/requirements list for material T-FF9## in plant 1100. 2-2-1

2-2-2

Write down the data displayed in this list in the following table: ! "#$%!

&'(!%)%*%+$!

'%,-$.'%/0!/$1!

23#4)#5)%!/$1

What do the MRP elements displayed in the list mean? STOCK: ____________________________________________________ ORDER: ____________________________________________________ ORDER: ___________________________________________________

2-3

Carry out single-item multi-level planning for your material T-FF9## in plant 1100. 2-3-1

Display the MRP list for the material after the MRP run. Write down the data displayed in this list in the following table: "#$%!

&'(!%)%*%+$!

'%,-$.'%/0!/$1!

23#4)#5)%!/$1

What changes occurred or additional items added during the MRP run? ______________________________________________________ 2-3-2

Display the planned order the system has created from within the MRP list. Display the account assignment data in the planned order. To which sales order account has the system assigned the planned order? Sales order: _______________________________________________ Display the material components for the planned order. Record them below: ______________________________________________________ ______________________________________________________ ______________________________________________________

ÂŠ SAP AG

TERP10

21-6

2-3-3

Branch from the MRP list to the MRP data for your material T-FF9##. Which strategy group has been defined for the material on the !"#$% view. Strategy group: ______________________________________________

2-3-4

Display the MRP list for your material component T-RF7##. Write down the data displayed in this list in the following table: !"#$%

&'(%$)$*$+#%

'$,-#.'$/0%/#1%

23"4)"5)$%/#1

Display the pegged requirement for the dependent requirement. Follow the route right back to the sales order.

What is the pegged requirement for the dependent requirements? ______________________________________________________ 2-3-5

Branch from the MRP list to the MRP data for material component T-RF7##. Which value has been entered in the &'()*)(+,-./0--1 field (dependent requirements indicator for individual and collective requirements) in the !"#$2 view. Individual/Collective: __________________________________________ Which functions do the different settings for the dependent requirements indicator have in make-to-order production? ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ How does the indicator setting 3 affect material component T-RF7## in your example? ______________________________________________________ ______________________________________________________ ______________________________________________________

ÂŠ SAP AG

TERP10

21-7

TERP10

21-8

!"#$%&'%()*$)+,)'*-.&/'01+,)'.$22+()*$)+34$.-&/'0+34$)./2$2+ 50/&1+,)'*-.&/'0+,6"00/07+8+34$.-&/'0+ 9':/.1+,)'.$22+()*$)+34$.-&/'0;+<''*2+=$.$/:&;+"0*+ >'2&/07+ At the conclusion of these exercises, you will be able to: • Describe how planned and actual costs are calculated in a process order • Describe the special aspects of process order execution in make-toorder production • Describe how a process order is settled in a make-to-order environment You will convert the planned order created for the sales order to a process order. You will execute the process order and analyze the planned and actual costs. You will settle the process order.

3-1

In collective conversion for planned orders, convert the planned order for material TFF9## that the system has created in the MRP run for the sales order to a process order. Enter the following criteria to select the planned order: Plant: 1100 MRP controller: F## Sales order: !"#$%&'()&%"$*)$%+#,-)$%.$",%/0)%1$)23"#&%)4)$53&)&% % Use order type PI01 for the conversion.% % Write down the number of the process order created after planned order conversion. Process order number: ______________________________________________

TERP10

21-9

3-2

Display your process order. 3-2-1

Which activities did the system carry out automatically after the process order was created? To answer this question, display the order statuses, the !""#$%&'()* detail screen for the order header, and the material list. ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________

3-2-2

Display the settlement rule for the process order. To which settlement receiver are the process order costs allocated during the settlement procedure? ______________________________________________________

3-2-3

Display the costs incurred by the process order. Write down the planned and actual costs in the table below. You will have to change the layout of this report to include planned costs, as the default layout only has target and actual costs.

3-3

!"#$#%&

'()%&

*+,-)(&

'()%%./& 0,1

*+,-)(&0,1&

&&&2345677&

&&&2345877&

&&&2345977&

2:,)(&;::/<&=<<-.<&&

>?@ABC>?A&&

2:,)(&&&

Display the stock/requirements list for your product T-FF9##. Write down the data displayed in this list in the following table: D),.&

E4'&.(.F.%,&

4.+G,B4.0/&0,1&

*H)#()I(.&0,1

ÂŠ SAP AG

TERP10

21-10

3-4

Select the control recipe for your order in the control recipe monitor and send it to its destination. Write down the control recipe number: ___________________________________

3-5

Maintain the PI sheet that was created by sending the control recipe. Enter your signature to report the start of phases. Enter your user name, PI-## and confirm the signature by entering the password PASSWORD##. Report the actual quantities of the ingredients charged. Use the input help (F4) to display the target quantities as default values and copy them to the !"#$%&'($%)#*#+ fields. The produced quantity you report in the last phase should be the same as the planned quantity. When you have finished maintaining the PI sheet, set it to complete.

3-6

Select the process messages created by maintaining the PI sheet in the message monitor Send the process messages to their destinations.

3-7

Display the stock/requirements list for your product T-FF9##. 3-7-1

3-7-2

Write down the data displayed in this list in the following table: !"#$%

&'(%$)$*$+#%

'$,-#.'$/0%/#1%

23"4)"5)$%/#1

Which changes occurred in the stock/requirements list as a result of the delivery of the product? ______________________________________________________ ______________________________________________________ ______________________________________________________

ÂŠ SAP AG

TERP10

21-11

3-8

Display the stock overview for your product T-FF9##. In which stock column displayed in the overview, can the batch you just produced be found? __________________________________________________________ Display the detail data about the sales order stock. Write down the number of the sales order to which the sales order stock refers. Sales order (document): _____________________________________________

3-9

Display your process order. 3-9-1

Write down the quantity that was produced: _______________________________

3-9-2

Display the costs. Write down the planned and actual costs in the table below. You will have to change the layout of this report to include planned costs, as the default layout only has target and actual costs. !"#$#%&

'()%&

*+,-)(&

'()%%./& 0,1

*+,-)(&0,1&

&&&2345677&

&&&2345877&

&&&2345977&

2:,)(&;::/<&=<<-.<&

>?@@@@& *+,#A#,1&:B&)((:+C& D)+E#%.<&

F.G#,<&

H,1&:B&$::/<& D)%-B)+,-"./&

As a result of which business transactions did the system determine the actual costs? ______________________________________________________ ______________________________________________________

ÂŠ SAP AG

TERP10

21-12

3-10 Settle your process order in individual processing. 3-10-1 Write down the settlement sender and receiver that the system displays after the settlement run. Sender: _____________________________________________________ Receiver: __________________________________________________ Display the detail data about the sender and receiver. How does process order settlement affect the process order and sales order in terms of crediting and debiting? ______________________________________________________ ______________________________________________________ 3-10-2 Display the costs in your process order. Write down the actual costs in the following table: !"#$%&'&(&)$#%

*+$,-'%

./////% 0-1%(-$&23-'#%+")#,(&4%

56////% *+$373$8%"9%-''"+:%(-+;3)&#%

<&=3$#%

5>?///% @24&2%#&$$'&(&)$%A%(-$&23-'%

5>6///% @24&2%#&$$'&(&)$%A%3)$&2)-'% B2"+&##3)C%

!2&43$#%

D-'-)+&%

How does process order settlement affect the process order costs? ______________________________________________________ ______________________________________________________

ÂŠ SAP AG

TERP10

21-13

3-10-3 Display the cost report for your sales order. Write down the actual costs in the following table: !"#$%&'&(&)$#%

*+$,-'%

./0111% 234&3%#&$$'&(&)$%5%(-$&36-'%

./7111%234&3%#&$$'&(&)$%5% 6)$&3)-'%83"+&##6)9%

:&;6$#%

How does process order settlement affect the sales order? ______________________________________________________

ÂŠ SAP AG

TERP10

21-14

!"#$%&'%()*$)+,)'*-.&/'01+2'3-&/'04+ 50/&1+,)'*-.&/'0+,3"00/06+7+89$.-&/'0+ :';/.1+!"4&$)+<"&"+=')+,)'.$44+

1-1

!"#$%&$'%(→(!"#$%&'(#)*+*!"#&,--(→(./-',"*0/'/(→ ./-',"*1,&(2,-(→ 1,&(2,*/)$* ./',"(/3*4(-&(→(0(-23/5( Recipe group: T-RC9## Select: )*&+, 1-1-1+

>$./;$+*$4.)/;&/'01 Fertilizer, liquid, form SX

1-1-3

2$3$.& the -.&+,$./% tab ,)'*-.&1+ + + + + T-FF9## Fertilizer, liquid, form SX !"&$)/"3+.'?;'0$0&41+ T-RF7## Ammonia T-RF9## Potassium sulfate T-RF8## Phosphoric acid Select: )0$&

TERP10

21-15

TERP10

21-16

!"#$%&"'() *'&%+),-".$/%&"'),#0''&'1)2)345/$%&"') 6"7&/+)!0#5()8-.5-)0'.)90%5-&0#):5;$&-5<5'%(),#0''&'1)

2-1

!"#$%&$'%!!!"#$%&!#'(!)*&+,*-.+*/'!!!"#$%&!!"0,(%,!!!1,%#+% 2-1-1

8-.5-)%=75+)) ) ) ) !0#5()"-10'&>0%&"'+)) ) ?&(%-&@$%&"')/A0''5#+)) ?&B&(&"':)) ) ) ) )

OR "Standard order" 1000 10 00

Choose ()&*+, The -+*.&*/0&.)1.+1/2+1*+3/24*+4$*5 screen appears. Enter the following data: !"#.C%")70-%=+ ,$-/AD"-.5-)'"D+)))

F-1001 12389-##

In the 0.6*% tab Enter the following data: :5;D).5#&BD).0%5+)) ) 90%5-&0#+))) ) ) 8-.5-);$0'%&%=+)) ) !*)E!0#5()$'&%F) )

7"1.8/9/:/5**;%/ T-FF9## 10,000 L (liters)

Save the order. Acknowledge any messages regarding the recalculation of dates by selecting ()&*+. The system displays the order number in the status bar at the bottom of the screen. Note that a new sales order is ready to be entered after your order has been saved. Choose <.'; to exit sales order processing. Select '/ when asked if you would like to save this new incomplete order.

ÂŠ SAP AG

TERP10

21-17

2-2

!"#$%&$'%(!()*"+,'&$"-(.()*"'/%%(!"01)(!(2345,4&$"-%(!(6&"'781/9:&%(!$%&( ( !"#$%&"'() T-FF9## *'"+#() 1100 Select: !"#$% 2-2-1

2-2-2

,"#$)

!-*)$'$.$+#)

-$/0#1-$23)2#4)

56"&'"7'$)2#4

&'()*+

Stock

)

&'()*+

Order

)

,$-./%$0$"#+ ()#$+

Order

10,000 (-)

10,000-

Place your cursor on the MRP element column and select (F1). STOCK: Plant stock ORDER: Individual customer stock for the sales order ORDER: Sales order The quantity of goods received and the requirement quantity for your sales order are both managed in the individual customer stock. Select: !1/#

ÂŠ SAP AG

TERP10

21-18

2-3

!"#$%&$'%(!()*"+,'&$"-(.()*"'/%%(!"01)(!(( )23--$-#(!(4$-#2/.5&/67(0,2&$.!/8/2()23--$-#( ( !"#$%&"'() T-FF9## *'"+#() 1100 Select: !"#$%&twice Select: !'(# 2-3-1

!"#$%&$'%(!()*"+,'&$"-(.()*"'/%%(!"(01) !"9832,3&$"-%(!(01)(!$%&( !"#$%&"'() T-FF9## *'"+#() 1100 Select: !"#$%&

& ,"#$)

!-*)$'$.$+#)

-$/0#1-$23)2#4)

56"&'"7'$)2#4

)*+,-&

Stock

)

)*+,-&

Order

)

10,000

10,000 (-)

./,""$+&0**+1& PlOrd. %$2$(3#& 4$56(%$7$"#& +,#$&

Order

During the MRP run, the system creates a planned order to cover the requirements that result from processing the sales order. 2-3-2

In the MRP list for material T-FF9##, position the cursor on the MRP element PlOrd. and choose the 8(13/,-&$/$7$"# button in the lower tool bar. Choose the 91107# tab to display the account assignment data for the planned order. The planned order has been assigned to the sales order account. In make-toorder production, costs are managed separately for each sales order. To display the material components of the planned order, choose the :*73*"$"#1&button. The following components are assigned to the order: T-RF7## Ammonia T-RF9## Potassium sulfate T-RF8## Phosphoric acid Select ;,2<&twice to return to the MRP list.

2-3-3

Double-click material number T-FF9## in the MRP list.( The =4.&> view of the material master appears. Choose the =4.&? tab. 8#%"#$94)9%:;0()20 "Make-to-order production" Select ;,2< Select !'(#

ÂŠ SAP AG

TERP10

21-19

2-3-4

!"#$%&$'%(!()*"+,'&$"-(.()*"'/%%(!"(01)(!"2345,4&$"-%(!(01)(!$%&(.( 04&/*$45( ( !"#$%&"'( T-RF7## )"#$*

!+,*$'$-$.#*

+$/0#1+$23*2#4*

56"&'"7'$*2#4

!"#$%&

Stock

100,000

'()*+,(-(./& #$/(&

DepReq

9,000 (-)

91,0000

To display the pegged requirements, position the cursor on the MRP element DepReq and choose 0(11(#&,()*+,(-(./2 button in the lower toolbar at the bottom of the screen.( To display the route to the sales order, choose 3,#(,&,"*/(. Your sales order is the pegged requirement of the dependent requirements. Select 45+/ Double-click material number T-RF7## in the MRP list.( ( Select the 6'0&7 tab. 8.3&6&39"'1/:''$/#&6$*%$29&%$-$.#;(*2 "Collective requirements only" Setting "8" in the individual/collective requirements indicator for material component T-RF7## implies the following: The dependent requirement is managed in the plant stock. Since there was no shortage in the plant stock, no purchase requisition was created. Settings "9" or " " would mean that dependent requirements would be managed in the individual customer stock. In this case, the system would create a sales order-specific purchase order. Exit the MRP List.

ÂŠ SAP AG

TERP10

21-20

!"#$%&"'() *'&%+),-".$/%&"'),#0''&'1)2)345/$%&"') 6"7&/+),-"/5(()8-.5-)345/$%&"'9):"".();5/5&7%)0'.) <"(%&'1)

3-1

!"#$%&$'%(!()*"+,'&$"-(.()*"'/%%(!(01)(!(( )23--/+(4*+/*(!(5"-6/*&(&"()*"'/%%(4*+/*(!(5"22/'&$6/(5"-6/*%$"-( ( ,#0''&'1)7#0'%+)) ) 1100 =;,)/"'%-"##5-+)) F## !0#5()"-.5-+)) ) !"#$"%&'()$"% ,-"/>)"-.5-)%?75+) PI01% Note: If a material number is displayed on this screen, remove before proceeding. % Choose the *+$,'-$%.$/$,-01&. icon. The 21//$,-03$%21&3$".01&%14%5/6&&$#%!"#$".7%80.screen appears. According to the selection criteria, the system only displays the planned order that was created for your sales order. Select the corresponding line in the list and choose the 21&3$"-%button on the lower toolbar. The system converts the planned order to a process order. The process order number is displayed in the status bar at the bottom of the screen. Select *+0-%twice.

3-2

!"#$%&$'%(!()*"+,'&$"-(.()*"'/%%(!()*"'/%%(4*+/*(!()*"'/%%("*+/*(!(7$%8239( ( ,-"/5(()"-.5-+)%% !"#$"%&'()$"% Select *&-$" Select 9-6-'. 3-2-1

After creating the process order, the system automatically carried out the following activities: Mat. availability check:

=@<= "Material committed"

Order release:

;3A "Released"

Control recipe creation:

<;<; "Control recipe created"

Batch master record creation for product T-FF9##:

B@!< "Batch assignment complete"

Also check the automatically created batch number in the :11#.% ;$,$0<-=>6/'6-01& tab ÂŠ SAP AG

TERP10

21-21

Select: !"#$ Select the %&&'()*+#,- tab Select the ."-+/0"1( 10(-)button See automatically assigned batch in the material list for the batch managed components.

3-2-2

Go to the order header. Select: the 2+"'+/ button ! Choose "#$%#&!!!'#(()#*#+(!&,)#. The process order costs are charged to your sales order number of the receiver category SDI (Sales document item) at 100 %. Select: !"#$ In the order header, choose -.(.!!!/.0(0!!!1+$)2030! ! The system determines the planned costs and quantities during process order creation. !"#$#%&

'()%&

&&&2345677&

*+,-)(&

'()%%./& 0,1

*+,-)(&0,1&

&&&&89:;<;;& &

&&&&&&&&&&:;;;&

&&&2345=77&

&&&&&&>?:<;;& &

&&&&&&&&&&&&6;;&

&&&2345:77&

&&&&&&99><;;& &

&&&&&&&&&&&&>;;&

2@,)(&A@@/B&CBB-.B&&

&&&&9;6?<;;& &

&&&&&&&&&&:6;;&

8?9;D98?;&&

&&&&&&&&9;<8:& &

&&&&&&&&&&&&&<69&

2@,)(&&&

&&&&99??<8:& &

At this stage, the system has not yet determined any actual costs. Actual costs are determined only after material withdrawals (for cost element 400000) and confirmations (for cost element 620000) have been performed. Select: 340-)-50#+

ÂŠ SAP AG

TERP10

21-22

3-3

!"#$%&$'%(!()*"+,'&$"-(.()*"'/%%(!()*"'/%%(0*+/*(!(1-2$*"-3/-&(!( 4&"'567/8,$*/3/-&%(!$%& !"#$%&"': T-FF9## ('")#: 1100 Select: !"#$%& *"#$+

!,(+$'$-$)#+

,$./#0,$12+1#3+

45"&'"6'$+1#3

'()*+&

Stock

'()*+&

Order

10,000

10,000 (-)

,-*""$)&.(()/& PR-ORD %$0$12#& 3$451%$6$"#& )*#$&

Order

Select: !71#& 3-4

!"#$%&$'%(!+)*"+,'&$"-(.()*"'/%%(!()*"'/%%(9:-:#/3/-&(!(( ;"-&*"<(*/'$=/(!(;"-&*"<(*/'$=/(3"-$&"*( ( ('")#7++ 1100 (%8.$99+8%2$%7++8%)$%&"569$% & Choose !"#$%: The ;("#%(-&3$012$&<("1#(%=&8>$%>1$? screen appears. Select your control recipe and choose @$"). After sending, choose the 3$A%$/B icon to update the list. The control recipe will now have the status @$"#. Select C*0D& Select !71#

3-5

!"#$%&$'%(!+)*"+,'&$"-(.()*"'/%%(!()*"'/%%(9:-:#/3/-&(!")>(%?//&(!(@$-+( ( In the Find PI Sheet screen, enter Plant 1100 and your process order. Select Execute. Select your PI sheet, then select the Maintain PI sheet button. & Enter your signature to report the start of phase 110. Enter your user name, PI-## and confirm the signature by entering your password. Report the actual quantities of the ingredients ammonia and potassium sulfate charged. Use the target quantities as default values and copy them to the E0#5*-&45*"#1#+ fields. Report the end of phase 110. Note that phase 210 is locked for maintenance until you have entered your signature to confirm the end of phase 110. Maintain phase 210 in the same way.

ÂŠ SAP AG

TERP10

21-23

When maintaining phase 220, report the quantity of the fertilizer produced. In our example, the quantity produced should be the same as the planned quantity. Use the default value for the !"#$%&%'()*+,"-., field. When you have entered the last signature to report the end of phase 220, set the PI sheet to complete. Choose!!"#$%&&'!!!(&'#')#*)+,-&'&.! ! Select: /#-0( 3-6

.)/0$'0*$#!!!1)23*'0)4#5#!1)*&$$#!#!1)*&$$#6747/&+&4'#!"6&$$7/&#!#6&$$7/&# +)40')1# # "#$%&'!! 1100 "()*+,,!)(-+('!!1*,.*($"23.*( ( Choose 4$%.*5 The 6*+-.77(8.77#9.(8+$&%+*:(8.77#9.7 screen appears. Select all process messages and choose the ;.$, button to send them. After sending, choose the <.=*.7> icon to update the list. The messages will now all have the status ;.$%. If some messages still have status ?+(3.(*.7"32&%%., or @.7%&$#%&+$(.**+*, try to analyze the error in the logs and send these messages again. Select /#-0( Select 4A&%

3-7

.)/0$'0*$#!!!1)23*'0)4#5#!1)*&$$#!##!1)*&$$#812&1#!#94:01)4+&4'#!# (')*;<=&>301&+&4'$#.0$'# # .$&+(/$#'!! T-FF9## "#$%&' 1100 Select 4$%.* 3-7-1

3-7-2

0$&+!

.1"!+#+2+%&!

1+*3&41+5-!5&6!

78$/#$9#+!5&6

?+,#'(

Stock

?+,#'(

Order

10,000

<.B"&*.2.$%( ,#%.(

Order

10,000 (-)

The MRP element for the process order was deleted as soon as product T-FF9## was delivered. The quantity produced is kept in the individual customer stock for the sales order. Select: 4A&%

ÂŠ SAP AG

TERP10

21-24

3-8

!"#$%&$'%(!()*&+,$*-%()*.*#+/+.&(!(0.1+.&",2()*.*#+/+.&(!( 3.1$,"./+.&(!(4&"'5(!(4&"'5(61+,1$+7( ( !"#$%&"'()) T-FF9## *'"+#( 1100 8,"#,*/(!(39+':&+( ( The batch you have produced is kept in the sales order stock.( ( Double-click the corresponding table line to display the detail data for the sales order stock. The number of your sales order is displayed as the document number. Select: !"#$%(In the dialog box)% Select: &'()

3-9

!"#$%&$'%(!)8,";:'&$".(<(8,"'+%%(!((8,"'+%%(6,;+,(!((8,"'+%%(",;+,(!(=$%>-*2( *%,-$..),%/$%() *+,-+%./01-+% Select: &.)-+ 3-9-1

The quantity produced is displayed on the 2-.-+"3%,")" tab in the order header. 0$'&1$%$/( 10,000 L (liters)

3-9-2

In the order header, choose ?"&"(!(@"%&%(!(A.*-2%$%( 2%&3&+)

*'"+)

4-#5"')

*'"++$/) 6#7

4-#5"')6#7)

)))89:;<==)

)

)))89:;>==)

)

)))89:;?==)

)

8,#"')@,,/.)A..5$.)

)

BCDDDD) 4-#&1&#7),E)"'',-F) G"-H&+$.)

)

0$I&#.)

)

J#7),E)3,,/.) G"+5E"-#5%$/)

)

The material withdrawals and confirmations performed for the order trigger actual cost determination. Note: In the display, the resource activities have been rounded down to full hours. Select: &'()% Select: 4-5% to exit the report Select: &'()% Select: !"#$ ÂŠ SAP AG

TERP10

21-25

3-10 !"#$%&$'%(!!)*"+,'&$"-(.()*"'/%%(!)*"'/%%(0*+/*(!")/*$"+./-+('1"%$-#(!( 2/&&1/3/-&(!"#-+$4$+,51(6*"'/%%$-#( ( "#$%&#''($)!*&+*,!! 1000 Select: !"#$%! ! -&.+&,!! ! &%'$%(")*+$%( /+%%'+0+$%!1+&(#.,!! ,)%%$"#(*-"#.( 2(34*'!5+*&,!! ,)%%$"#(/$0%( ( 6&#4+33($)!%51+, Automatic 6&#4+33($)!#1%(#$3, 7+3%!&8$, deselect 2/&&1/3/-&(!(78/',&/! 3-10-1 When the settlement run is completed, the 12#)03(4$##3$*$"#5(&%'$%(60782(987# screen appears. Choose the :$#083(387#7 icon. The 12#)03(4$##3$*$"#5(&%'$%(:$#083(987#(screen appears. Your process order is the sender and the sales order the settlement receiver. To display more detailed information on the corresponding settlement object, mark it and choose the 4$"'$% or ;$2$8<$%( button. By settling the order, the process order is credited. The sales order is debited with the material and production costs incurred during process order processing. Exit from the settlement processing screen. 3-10.2 !"#$%&$'%(!!)*"+,'&$"-(.()*"'/%%(!)*"'/%%(0*+/*(!(9$%615:( ( In the order header, choose ;"&"(!(<"%&%(!(=-51:%$%( ( After order settlement, the process order is completely credited. Its balance is now blank and there are new line items listed above the balance line indicating the settlement. Select: !=8#( Select: >$7(to exit the report Select: !=8#( Select: 602?

ÂŠ SAP AG

TERP10

21-26

3-10-3

!"#$%&$'%(!()*+,%(*-.(/$%&0$12&$"-(!()*+,%(!"30.,0(!(/$%4+*5( ( !"#$"%&& !"#$%&'()$(&*+,-$(& & Choose .*/$(0 The 12%3#"4&!/"*)"()&5()$(6&57$(72$8 screen appears. Choose 6-7$0"-8,-&(!(9"%&(0,4"0&.( ( :"&,;( You may find that the controlling area screen appears. Select the .9$:+/$ button to display the report. ( Since the process order has been credited, the sales order is now debited. The sales order is debited with the material and production costs incurred during process order processing. Select: .92/& Select: ;$%&to exit the report Select: .92/&

ÂŠ SAP AG

TERP10

21-27

TERP10

21-28

!""#$%&'()*((+,-%./0&-$(1'#/.0&-$(2 3#"#0&0&4#( 56$.76/0.,&$8(

9-$0#$0:* ! 3#"#0&0&4#(56$.76/0.,&$8(1'#/.0&-$

 SAP AG 2004

TERP10

22-1

!""#$%&'()*(+#"#,&,&-#(./$01/2,03&$4*(5$&,(678#2,&-#9

!,(,<#(2=$2;09&=$(=1(,<&9(0$&,B(C=0(A&;;(7#(/7;#(,=* ! :'";/&$(,<#(2</3/2,#3&9,&29(=1("#3&=%>7/9#%( 3#"#,&,&-#(?/$01/2,03&$4 ! @#923&7#(,<#(?/&$(9,#"9(=1(3#"#,&,&-#(?/$01/2,03&$4 ! :'";/&$(,<#(?/&$(10$2,&=$9(A&,<&$(3#"#,&,&-#( ?/$01/2,03&$4

 SAP AG 2004

TERP10

22-2

!""#$%&'$()*!+,&4A"$%&#*$)@>-'+$,4A"$%&#*$)@>-'+$,-

./01234*30:.8BC749

:,%;&)$%&#*,)<$),,+$)<= %()->?,+*"+(@>%'-=*,#,%'+()$%-= &)@*?(+,

4&F'DE&-,@*G#(H 4&F'DE&-,@*G#(H ?&)>G&%D ?&)>G&%D '>+$)< '>+$)<

.,+$(@DE&-,@ "+(@>%'$()

:&--*"+(@>%'$()

./01234*54!678749  SAP AG 2004

Repetitive manufacturing is mainly used for production with "#$"!%&'()*+!,+-.#/#+0 and "#$"! &1%1+#+#'2!&-+1!as well as /'3!%&'()*+!*'4%/15#+0.

TERP10

22-3

4$"/0#*5-2$#%6$($&/&/7$%8-.,9-3&,"/.:)% ;<-"-3&$"/2&/32%=>? 6$($&/&/7$%8-.,9-3&,"/.: ! !

!"#$"%&'($)%* !"#$%&#'%()*( * +,-.&/&'* -.#%($"/0#*1-2$#%("0#,3&/0.

J.&$:"-&/0.%09%6$($&/&/7$%8-.,9-3&,"/.: 8-2&$"%@-&-%8-.-:$A$.& B-E$2 4"0#,3&/0.%0"%8-&$"/-E%6$I,/"$A$.&2%4E-../.: ;-(-3/&'%6$I,/"$A$.&2%4E-../.: 8-&$"/-E2%8-.-:$A$.& D0:/2&/32%KL$3,&/0. +,-E/&'%8-.-:$A$.& ;0.&"0EE/.:% 5,2/.$22%J.90"A-&/0.%M-"$<0,2$% D0:/2&/32%J.90"A-&/0.%B'2&$A%

=A'BC4 4D8?% =A'BC4 ;68F%BC4%6GH*B@? =BC4%6GHF%BC4%C4!? =BC4%6GHF%BC4%C4!? =BC4%6GH%J8? =BC4%6GH%M8? =BC4%6GH%+8? =BC4%6GH%;!? =BC4%5M?%0"%% =BC4%6GH%DJB?

 SAP AG 2006

TERP10

22-4

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

 SAP AG 2006

Apart from the basic functions, repetitive manufacturing offers several other functions (see next slide).

TERP10

22-5

!+"#(0<@,1+0'7+*+%#%#?+'4,$9),2%9"#$&A' B/,",2%+"#1%#21'CDE =$/,$2+0'>9$2%#($1'()'7+*+%#%#?+'4,$9),2%9"#$& ! !"#$%#$&'()'(*+",%#($,-'.+%/(0'1/++%',$0'0#1*,%2/'-#1%'3#%/' 4#2"(1()%'5))#2+'-#$6 ! 7+*("%#$&'*(#$%'8,26)-91/ (milestone) ! :2%#($'2($%"(! 4,**#$&'()'%,6%#$& %('%/+'1;1%+.'91#$&'%,6%<8,1+0')-(3' .,$9),2%9"#$&

ďŁŠ SAP AG 2006

There is an MS Office link for the printing of shop papers and quantity papers (no shop floor papers!): MS Word can be used to print "#$%&'(")&*!+$',"-!.,$$'. and MS Excel for print -(.#&'/,!*(.'..

Beside +&0$1'"1.'"/0!#%"-2/'("), .&*$.1"%-$%1"%($)'$-!%$#$'('(3$!+&)24&/'2%()5 is also supported. This enables, for example, dealing with configurable materials.

To determine 6"%0!()!#%"5%$.. or to post /"+#")$)'!6(',-%&6&*. timelier, you can use a %$#"%'()5!#"()'!#%"/$-2%$ (only make-to-stock).

With regard to /")4(52%&7*$!+&'$%(&*., &/'(")!/")'%"* enables the automatic triggering of actions (for example, printing the component list).

The modelling of '&0'. along with the sequence planning it involves is represented by a separate function: '&0'17&.$-!4*"6!+&)24&/'2%()5.

ÂŠ SAP AG

TERP10

22-6

<(0'$)6

8-9&),."/(6/&9

3&'-/$&#.5(/-%&0'

:),-"2/-D9'0

A&#-0 (/,-/0

7#&))-, (/,-/0

317 1-"2.3&)45&%'4/$)6

7#&))-,.(/,-/0 B1A?C 3&)45&%'4/$)6

<()5$/9&'$().+2.0'(%@./-%-$"' A-''#-9-)'.(5.%(0'.%(##-%'(/

:)'-6/&'$() +$';.?3

:)=-)'(/> 9&)&6-9-)'

<&"&%$'>./-D4$/-9-)'0."#&))$)6

!""#$%&'$()*+$,-."/(%-00-0

:)'-6/&'$() +$';.78<

ďŁŠ SAP AG 2004

The complex process chain from independent requirements to the goods issue of the finished product is reproduced in a "#$% version in repetitive manufacturing.

Typical features are, for example, the use of planned orders for production (Planned orders are %&'! (&%)#*'#+!'&!,*&+-('.&%!&*+#*/. They only obtain the new order type *-%!/(0#+-"#!1-$%'.'2! 34567 when the production version is assigned.) as well as the confirmation of the finished product with simultaneous backflushing of the components used.

ÂŠ SAP AG

TERP10

22-7

!"5#$%-<"#"-=+%-0$;$#&#&>$-!"/1=".#1%&/2 0$;$#&#&>$-?=2-&/4&."#+%-"/4-0@!-;%+=&'$

!"#$%&"'

3%+41.#&+/->$%5&+/

()!

!"#$%&"'-()!

3%+41.#&+/-'&/$-"5-6+%,-.$/#$% (or as an exception, as a line hierarchy)

*+%,-.$/#$%

0"#$-%+1#&/2-7+%-5#"/4"%4-%+1#&/28 0+1#&/2

0+1#&/2

951"'':-+/$-+;$%"#&+/ <$=&/&#&+/-+=-;%+41.#&+/-%"#$ (quantity per time)

ďŁŠ SAP AG 2004

To allow a material for repetitive manufacturing, you set the !"#"$%$%&"'()* "#$"%&'()!in the *&'+)"&,!*&-'+)!)+%()$ (in the (!+,'view). This means you can use all the various production versions of this material for repetitive manufacturing (that is, you can set the indicator !"#"$%$%&"'()*' -../0"1')/2'&"23%/4'in the production version)5'

The ./0!defines the 1,&##+$!*&'+)"&,!%(#-2*1'"(#!for the components.

In the 3$-$637./4*'$"8$ of the BOM item (+2/169$%/4'3$/2-*"'./9-$%/4 field:, you can define the'"--2+! -'()&3+!,(%&'"(#!from which components are!to be 4&%56,2-7+$8

9)($2%'"(#!,"#+-!are usually created as simple :()5!%+#'+)-. In the work center, you define from when and to when the production line is available. The production line created as the work center is entered in the production version in the +2/169$%/4'.%4" field5' This same work center is specified in the single operation of the routing. Production lines that have more than one work center can be represented in a!,"#+!7"+)&)%7;8

In repetitive manufacturing, the )(2'"#3!defines the production rate (quantity per time unit) used to produce materials on production lines. The production quantities are scheduled according to the production rate, and capacity requirements are calculated for this production quantity. The routing therefore provides the 4&-"-!6()!,+&$!'"*+!-%7+$2,"#38 In repetitive manufacturing, work centers are not usually used to describe the actual operations to be performed. Therefore, routings in repetitive manufacturing often only have (#+!(1+)&'"(#8 The total production rate of the line is specified in this operation. It defines how many materials per time unit can be produced on this production line. In the single operation, you enter the production line as the work center.

Two different routings are available: -'&#$&)$!)(2'"#3- and )&'+!)(2'"#3-. Rate routings are specially designed for the needs of repetitive manufacturers and can be used instead of standard routings for organizational purposes. You can, however, also use standard routings for repetitive manufacturing.

ÂŠ SAP AG

TERP10

22-8

.%,-/+#&,0 4$%*&,0*

!"#$%&"'()"*#$%(%$+,%.%,-/+#&,0(1$%*&,0 2 .%,-/+#&,0(1$%*&,0 3 9,/#&0:

! 9$+$&1&0: *#,%":$ ',+"#&,0 ;"**$)6'<= ! .%,8,*$- &**/$ *#,%":$ ',+"#&,0 ;+,)8,0$0#*= 5$*+%&6$* #7$ 8%,-/+#&,0 8%,+$-/%$

ďŁŠ SAP AG 2004

The production version contains data relevant to all manufacturing environments. This following data is included in a production version: # The fields "Valid from" and Valid to" define the period of validity of the production version. # The "To location" is the proposed receiving storage location. # The fields "BOM alternative" and "BOM usage" define which BOM is to be used in manufacturing. # The task list fields for detailed, rate-based and rough-cut planning. Usually, you enter a group and a group counter in the rate-based planning fields. The values entered are used for scheduling and capacity planning. # The fields "From lot size" and "To lot size", define the area of validity for this version. # The field, "production line" defines the work center (production line) for assigning production quantities in the repetitive planning table. In repetitive manufacturing (in the planning table), the system only displays the capacity requirements for this work center. To be able to carry out capacity planning, this production line must exist in the routing.

The creation of a production version is mandatory for repetitive manufactured products. Production versions are optional for discrete and process manufactured products.

ÂŠ SAP AG

TERP10

22-9

!"#"$%$%&"'()*+,)-$+.%*/0'1.2-"33'4526

B"$$5"8"*$'=:'#.29+-$ -23$'-255"-$2.

!"7+%."8"*$3 15)**%*/'2,'5%*" 52)9%*/')*9 -)#)-%$:'-;"-<

M 4%*)5'-2*,%.8)$%2* )*9'3$2-<'."-"%#$ 6%$;'-28#2*"*$ =)-<,5+3;%*/

H >?1'9"$".8%*)$%2* @2#$%2*)5'6%$; ."#2.$%*/'#2%*$ =)-<,5+3;A

D&)%5)=%5%$: -;"-< 1.%*$%*/'2, 2#".)$%2*)5' 8"$;29'3;""$ 1.%*$%*/'2, 9%3#)$-;'5%3$

()$".%)5'3$)/%*/

1.29+-$%2*'"C"-+$%2* ďŁŠ SAP AG 2004

Despite the lean implementation of basic functions, a "#$%&'!()!*+,-.-,-&/ are possible in repetitive manufacturing.

The main aspects are the 01*""-"2!()!1-"&!1(*3-"2 and the (usually simultaneous) +*0*+-,4! $("-,('-"2.

You can, for example, use the planning table (multi-level access) to check the *.*-1*%-1-,4 of assemblies for the finished product.

The worker gets the information he or she needs from the (0&'*,-("*1!$&,5(3!/5&&, (description of the operation if necessary) and from the 3-/0*,+5!1-/, (materials, quantities, and dates).

6*,&'-*1!/,*2-"2 is done by stock transfers or KANBAN provision to the line.

During production, '&0(',-"2!0(-",!%*+7)1#/5 can be used to determine work in progress.

After order processing, the finished product is +(")-'$&3 to stock. This means both the 2((3/! '&+&-0, as well as the +($0("&",!%*+7)1#/5 is posted.

Costs are settled by means of a 0'(3#+,!+(/,!+(11&,('8

ÂŠ SAP AG

TERP10

22-10

!"'(()(*+,)(-+,.'%)(*/+#0-$0)-1+

!"#$%&

!"#$%& !"#$%& !"'((-%+.$%-$ '22)*(3-(4+52)(*&&& #64).('""7 =>?+6"'(()(*+4'@"-> 8!#+6$.%594 6"'(()(*+4'@"-

8"4-$('4)0-+2-"-94).( :'54.3'4)9'""7; <5.4'+'$$'(*-3-(4 :'54.3'4)9'""7;

 SAP AG 2006

You can use any of the following three options to plan the line loading (dispatching of planned orders on the production line): •

"#$%&'($)*%!+%#%,$)-'.! −

•

If !"#$%!"&%'(#)*!/&-01,$)-'!*%&+)-', that is, for example, only one line, is available, you can set the alternative selection indicator " in the material master (#$%& view). Planned orders are then (1$-2($),(##3 assigned to this line. If several lines are available, the system assigns the first line it finds. Since this reduces your freedom when planning the line loading, we recommend using this option only if there is only one valid production version or production line.

41-$(!(&&('5%2%'$.! −

If +%*%&(#!/&-01,$)-'!#)'%+ are available but one is preferred (for example, it is always to reach full capacity load), you can use quota arrangements to distribute the remaining quantity to the alternative lines. To do so, you maintain the '()*+!+,,-!(.+/0 field in the #$%" view in the material master and trigger quota maintenance in the #$% menu under #+.*0,!1+*+. We recommend using quota arrangements only for rough-cut planning with (00)$)-'(#! /-+$/&-,%++)'5%in the planning table.

TERP10

22-11

6.#&;19(F;%(!"1+"'(:'"11&1>(;F(0&1$(0;")&1>

,"-".&#/()"#" 0&1$(2 3$4+&%$5$1# 67"&'"8'$ 0&1$(< 3$4+&%$5$1# 67"&'"8'$ !"#$%&"'()"#"

*+$ ? @ @ ? @ @

A A 2B A A 2B *+$

!"#$%&"'(6 :, 3$4+&%$5$1#9 :, <AA((( 67"&'"8'$(4#/ :%;)+.#&;1('&1$(2 :, :%;)+.#&;1('&1$(<(((((((((((((((((((((((( :, =;#(/$#("99&>1$) :, A(((

AEIAJI((((((((ACIAJI 2AA 2B 2B A A 2B

CA D 2B 2CA <E 2B

!;1&#;%&1>G ,"-".&#/ +#&'&H"#&;1

AEIAJI((((((((ACIAJI 6.#&7&#&/G 699&>1 '&1$9

2AA <AA((( 2AA <AA(((

CA 2CA A(((

ďŁŠ SAP AG 2006

The planner uses the "#$!%&'(()(*!+',&- to process the master plan. He or she can check the production quantities, change them if required, and create new production quantities (planned orders). He or she can determine the capacity utilization of the production line as well as the availability situation of the products. In addition, he or she can display the source of the capacity requirements (pegged capacity) by double-clicking the capacity requirements.

Since planning in repetitive manufacturing is carried out in a quantity- and period-based manner, the display in the planning table is quantity- and period-based. You can choose any planning period (shift, day, week, month, planning calendar period).

In the '..)*(/-(+!/01-, the planner can assign the production quantities (planned orders) to a production version and thus to a production line. If this was already done in MRP, he or she can also change existing assignments. Planned orders that are assigned manually to a line obtain order type PE (run schedule quantity) and are usually fixed. By means of the repetitive manufacturing profile, the fixing behavior can be limited to the planning time fence per material or deactivated in general.

In addition, you can choose !"#$%&"'()*+$%+&$, to go to a separate material overview displaying the exception message and range of coverage situation.

Changes you make in the planning table are not written to the database unless you save them.

ÂŠ SAP AG

TERP10

22-12

%(-2.1(/&<-(=1)=&7>-1,)3 5://&/13-? <-(=1)=&8.,;&3-,.(=2 /,+(-1,)&/2@2/

%%#C%&$(.2D,:32&%=;012$1-&#/)*"1"+$,$1-

!13-&,8&A()*()3 -,&*2&;,@24 5://&/13-? 2@2)-#4.1@2)&A()*()

'()*() +,)-.,/

5://&/13-? !13-&,8&-.()382.&.29:1.2;2)-3 B.()382.&,.42.3

!"#$%&!"#$%&'($)*+,./(-$,

%(-2.1(/&13&,.42.24

E2/2(32&,.42.&>(.-3 51+A&>(.-3

5.,46&,.42.

7.42.#*(324&+.2(-1,)&,8 -.()382.&.29:1.2;2)-3 0,)-(1)2.&13&,.42.24

0.(-2&>(.-3 ďŁŠ SAP AG 2004

mySAP ERP has "#$%&'(!)$&*+,'$+( for *&-.$&//%-0!1#.+$%#/!(.#0%-02!

! a) Warehouse management with the component 33453!(Inventory Management) b) Replenishment control with the component 678978 c) Handling of storage bins and replenishment control with the component :;4<3! !!! (Warehouse Management) !

The )'//!/%(. enables processing by means of .$#-(=+$!)&(.%-0(!&-!.>+!(.&$#0+!/&*#.%&-!/+"+/, supports +"+-.4,$%"+-!678978, and enables integrating <#$+>&'(+!3#-#0+1+-.!?<3@.

Since pick part processing is &$,+$4A#(+,, the <#$+>&'(+!3#-#0+1+-.!BC(.+1!prefers to use $+/+#(+!&$,+$!)#$.(!for -&-!&$,+$4A#(+,!$+)+.%.%"+!1#-'=#*.'$%-0:!

D+/+#(+!&$,+$!)#$.(!are &$,+$+,!1#-'#//C.!Here the required quantity is calculated from the target quantity of the components of the selected orders that have been released.

Both pick part processing and crate part processing can be used when the typical repetitive manufacturing functions (for example, the planning table) are used AC!1+#-(!&=!)$&,'*.%&-!&$,+$(.

ÂŠ SAP AG

TERP10

22-13

!"#$%&'()*"+,*-..,(*/0#0123

Upload PDC interface

Manual entry ;8.,'#3*#.(3 #.&&0#3.8

-..,(*80#0123 .% %1+1()0, 28.,'#3(

4"51+6*7"#$%&'()0(

43"+,"8,*"#31.+(*'(1+6*7"#$%&'()1+6 ,"3"

-..,(*1(('0 .%*#.92.+0+3(

:2,"30*(3"31(31#(

;8.,'#31.+ #.(3(

/0,'#31.+*.% ;<*=8,>

 SAP AG 2004

The "#$%!&'()*+,-) can be used for .,-/+0123&'4!+*56!$78!292()62. A separate transaction (MFBF) is available for 6,'1,0!)'(*9 of backflushes in the SAP R/3 System.

By posting the goods receipt for the finished products during backflushing a number of different actions are performed by default (controlled by the *):)(&(&;)!6,'1+,-(1*&'4!:*5+&0)): •

Goods issue posting for the components used (usually by .,-/+0123&'4)

•

<(,(&2(&-2!1:=,() in the Logistics Information System (LIS) or the Business Information Warehouse (BW)

•

>)=1-(&5'!5+!*1'!2-3)=10)!?1,'(&(&)2@:0,'')=!5*=)*2 and the connected capacity requirements on the production lines

•

Posting of :*5=1-(&5'!-52(2 incurred (material costs, production activities, overhead costs) to a product cost collector

•

7,(,!)'(*9!=5-16)'( creation!

•

Other optional actions (see !"#$%&' in the REM backflush transaction) include the following: consideration of 2)(1:!-52(2 for lot-size independent material quantities, posting of -56:5')'(@,22)6.09!2-*,:, -500)-(&;)!)'(*9 for different materials of a line, archiving of .,-/+0123!=5-16)'(2, pure 455=2!&221)!.,-/+0123 or pure!,-(&;&(9!.,-/+0123 (more/less activity), *):5*(&'4!:5&'(!.,-/+0123, =)-51:0)=!.,-/+0123&'4!:*5-)22)2, ,44*)4,(&5'!as well as various :52(:*5-)22&'4!,'=!*);)*2,0!5:(&5'2. In addition, sales-order based production enables .,-/+0123&'4!A&(3!*)+)*)'-)!(5!(3)!2,0)2!5*=)*.

TERP10

22-14

1'*"&+).B%,").+%C4(56/-$7 9:4;*/'<

Receiving storage location

,&"#-(+)".%/).'%0 Work center 1-1

Work center 1-2

Work center 1-3

Work center 1-4

!""#$%&'(')*+

=*'&4+)".%0>%%%%=*'&4+)".%?>%%%=*'&4+)".%@>%%%=*'&4+)".%A>

!""#$% )$$-'$ Issuing storage location

Issuing storage location

1'*"&+2%*").+%34(56/-$7 1'*"&+2%*").+%34(56/-$7

1'*"&+2%*").+%34(56/-$7 8)+7%!1

ďŁŠ SAP AG 2004

"#$%&'(): A long production line with *)%+$'!*$&,!-(.$ exists. However, the goods issues for the first components at work centers 1-1 and 1-2 are to be posted timely and not by backflushing with final confirmation at the end of the production line.

During final confirmation, all components used along the production line are usually backflushed. If there are long lead times, the +)),/!(//0$/!1)'!-2$!#).3)%$%-/ may be posted much later in the system than after they have actually been withdrawn physically.

In this case, it makes sense to use the '$3)'-(%+!3)(%-!4&#51*0/2 to timelier post the withdrawal of components (and production activities) after operations already completed. The above example contains the three reporting points connected with operations 10 (work center 1-1), 20 (work center 1-2), and 40 (work center 1-4).

Prerequisite: In addition to having &#-(6&-$,!'$3)'-(%+!3)(%-!4&#51*0/2 in the '$3$-(-(6$! .&%01&#-0'(%+!3')1(*$, the relevant work centers must exist, and the operations must be available in the routing and defined as '$3)'-(%+!3)(%-/ by means of the #)%-')*!5$7.

Depending on the application, )3-()%&*!)'!'$80('$,!'$3)'-(%+!3)(%-!4&#51*0/2 is possible and makes sense.

ÂŠ SAP AG

TERP10

22-15

!"#$%&'6%&#(%) :;1,-).<'Printing the component list for c!"#$%&'()*+ material

!"#$%&'"%&#(%) *($&#$&+'"%,-%&.&#')$/# 0%('-)1&&.2'%(2.(

6%,-%&.&#/ 171$)18).9

3//4$&+'/#%(1+.')%"1#$%&'5

ďŁŠ SAP AG 2004

The !"#$%&'($&()*+&&,-(%.-,.!function provides a solution for an interface to external assembly control systems. This is used to "#$%&'(#!)#*+#(&&!$"!",(!$&&(-./0!/1%( and other dependent actions to the 234!20&"(- using a standard interface or an adjusted interface.

The following &"$%5$#5!'6%7"1*%& are available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

You can use this function to execute one or more actions for a series of planned order simultaneously. Without this function, you would have to execute these actions individually per planned order online. Furthermore, action control defines <,17,!$7"1*%&!$#(!$//*<(5 and ",(! &(C6(%7(!1%!<,17,!",(!$7"1*%&!$#(!"*!.(!7$##1(5!*6" The date and the time of the last action are then saved in the planned order.

H;(76"1%+!$7"1*%&: To execute actions, you must maintain a report that transfers the customerspecific data for the action. You can use the /0,"1#,(!"#$%&!transaction in the MRP menu as an example. To print the planned order component list, the system uses the printer defined in Customizing for MRP in the activity 2.%"1.,3,&#(2.%)%'+*'(45(2*+&&,-(6.-,.'(45(7,8$&,(9+:%1#(8%.(;%3)%&,&#( 9$'#.

ÂŠ SAP AG

TERP10

22-16

!"#$%&'()$%*%!+',)$%-.+",/0$12'34$',%!5!6 &'()$ ;+",/0$%0"#$%0"33'0$"+

Costing document from material costing

.+",/0$%0"#$%0"33'0$"+

Material cost Production costs Overhead costs to material 11 10 8

=4$'+)43 >)$?,+4>43

.+"0'##)7@ .+"0'##)7@

!"78)+94$)"7

:"",# +'0');$

1 5

2 4

<'$$3'9'7$ <'$$3'9'7$

!+',)$%;+",/0$%0"#$%0"33'0$"+ !+',)$%;+",/0$%0"#$%0"33'0$"+ :2%A43/4$)"7%0"7$+"3

<'$$3'9'7$%;+"8)3'

Material stock account (quantity * standard/price acc. to valuation variant) Plant activity account (quantity * price acc. to valuation variant)

ďŁŠ SAP AG 2004

Actual costs at time of settlement

Settlement account (acc. to allocation structure) Plant activity account Difference account

"#$$%#&#'$ in repetitive manufacturing is always (#)*+,-./0#, based on the 1+0$0!+2!$3#!()+,41$! 1+0$!1+%%#1$+)!5()+,41$-)#%/$#,!1+0$!+.6#1$!1+'$)+%%*'78.!

When executing 1+'2*)&/$*+'0!in repetitive manufacturing, the &/$#)*/%!1+0$0 for the components and the ()+,41$*+'!/1$*9*$*#0 (only if a material cost estimate with price update was carried out in advance) are automatically posted to the product costs collector during backflushing. The product cost collector is debited with the material costs and production activities (in the repetitive manufacturing profile, you can define whether /1$*9*$:!./1;2%403!is to be made with reference to the material cost estimate or the version-specific cost estimate). Morevover, the product cost collector is credited with the valuation price (materials controlled with standard price) or with the moving average price of the assembly (materials controlled with the moving average price).

<9#)3#/,0!are not determined with reference to an operation (that is, not for each goods movement or activity confirmation). Instead they are determined periodically during period-end closing in Controlling by way of an overhead structure and are posted to the product cost collector. There is a separate transaction in the !"#"$%$%&"'()*+,)-$+.%*/ menu for this.

It is possible that components different to those planned are used in production or that the overhead cost rates change. This results in!9/)*/'1#0!in the product cost collector and 0#$$%#&#'$!must be executed. The aim of settlement is to completely credit the product cost collector. During settlement, the costs not yet credited to the product cost collector are transferred; for a material that is valuated using the standard price, the variant costs are posted to the price difference account.

ÂŠ SAP AG

TERP10

22-17

<##+'1&"(=;(>+#+)&)&4+(?07@;(A'&)(B655%-C

:/6(%-+('/9(%3$+()/; ! !"#$%&'()*+(,*%-%,)+-&.)&,.(/0(#+-&/123%.+1( -+#+)&)&4+(5%'60%,)6-&'7 ! 8+.,-&3+()*+(5%&'(.)+#.(/0(-+#+)&)&4+(5%'60%,)6-&'7 ! !"#$%&'()*+(5%&'(06',)&/'.(9&)*&'(-+#+)&)&4+( 5%'60%,)6-&'7

 SAP AG 2006

TERP10

22-18

!""#$%&'()*(+'#,-&.#.( /$&0*( 1#"#0&0&2#(34$564-05,&$7( 89"&-*( 34.0#,(:404( ( At the conclusion of these exercises, you will be able to: • Name the main master data for repetitive manufacturing • Explain what is special about the master data for repetitive manufacturing

You work for a company that uses repetitive manufacturing to produce PCs on two production lines. You are a member of the SAP project team responsible for implementing the functions of SAP SCM !"#"$%$%&"'()*+,)-$+.%*/. You therefore first try to get a general overview of the basic master data for repetitive manufacturing. In particular, you look at the master data for the PC T-F10## (material master, BOM, routing, and work center as well as the product cost collector from Controlling).

1-1

Name the ;4.&-(<97&.0&-.(=4.0#,(%404 for repetitive manufacturing. ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________

TERP10

23-1

1-2

In the Logistics folder in the R/3 menu, navigate to the !"#$%&"'(!")#$% of PC *+ ,-.// (## = your group number), !"#$ view, 0'"1#(-2... Use the change mode (transaction MM02). Name three material master settings that are specific to repetitive manufacturing: ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ 1-2-1

Display production version 0001. Check the consistency of the combination of BOM and routing by choosing %&'().

1-2-2 Which production line is entered in production version 0001? ______________________________________________________ 1-2-3 Write down the group counter of the rate routing entered: ______________________________________________________ 1-3

Check the !"#$%&"'(345 for material T-F10##in the Logistics master data. How many "))$!6'&$) are on the hierarchy level directly below the finished product? ____________________________________________________________

1-4

Display the %"#$(%78#&19 for material *+,-.//:(0'"1#(-2.. in the Logistics master data. 1-4-1 How many different %78#&19) are displayed in the overview? ______________________________________________________ 1-4-2 Select the first routing with group counter 1 and choose *+',-./012. What is special about the routing? ______________________________________________________ ______________________________________________________ 1-4-3 Name the ;7%<(=$1#$% involved and the 0%7>8=#&71(%"#$ planned: ______________________________________________________ 1-4-4 Exit the operation overview and go back to the %"#$(%78#&19(7?$%?&$;. Which work center belongs to group counter 2? ______________________________________________________

ÂŠ SAP AG

TERP10

23-2

1-4-5 Write down the group counter number and compare it with exercise 1-3-3. Note: You find the group counter number in the rate routing header data. ______________________________________________________ 1-4-6 Does production version 0001 enable repetitive manufacturing with the two routings? Give reasons. ______________________________________________________ ______________________________________________________ 1-5

In the !"#"$%$%&"'()*+,)-$+.%*/ menu, check in the master data whether a !"#$%&'( &#)'(&#**+&'#" already exists for material T-F10## in plant 1200. Note: To do so, you must activate the field next to the material in the display transaction. How many product cost collectors exist and how are they assigned? ____________________________________________________________ ____________________________________________________________

ÂŠ SAP AG

TERP10

23-3

TERP10

23-4

!"#$%&'#'( )*&+,( -#.#+&+&/#(01*231%+2$&*4( 56.&%,( 7*+#4$1+&6*(8&+9(:$6;2%+&6*(:<1**&*4(1*;(0-:(( At the conclusion of these exercises, you will be able to: • Create a quantity- and period-based master production schedule for repetitive manufacturing • Interpret the results of a planning run in the stock/requirements list

In your plant 1200 in Dresden, you produce PCs. To achieve shorter delivery times, you execute planning for assembly production (make-tostock strategy) together with the !"#$$%$&'(%)*+,)'-%$#"'#../01"2 strategy (make-to-order) for the finished product. This means that the last step of final assembly is made only #-)/3 a corresponding sales order was received. First, check whether the master data for materials T-F10## (PC) and TB10## (motherboard) and then create planned independent requirements. 2-1

Make sure that for the finished product T-F10## the correct settings have been made for the strategy groups in the material master (plant 1200, 45!6 view): 50 – Planning without final assembly:

2-2

Is the material allowed for repetitive manufacturing? Note: Check the settings in the material master, 45!7'view and the release indicator (584'#""+(/9) in the relevant production versions.

2-3

Now create .<1**#;(&*;#.#*;#*+($#=2&$#>#*+' for the finished product in your plant 1200: Menu path: :+&%.)%;.'!'!3+9,;)%+$'!'!3+9,;)%+$'!"#$$%$&'!'</0#$9'4#$#&/0/$)'!' !"#$$/9'=$9/>/$9/$)'5/?,%3/0/$).'!'@3/#)/ Data: Values: Material Plant Planning period

(

5?@ABCC ADBB E(

(

TERP10

23-5

In the next screen, choose the !"#$%& '()$* tab. Create a planned independent requirement with a requirements date for the !"#$%&""' (enter the calendar week in the format &""'()"*+). The planned quantity should be ,-- ./"0"1. The quantity with period indicator 2 is to be distributed over the individual working days. Therefore, set the + (day format) indicator in the !,-. column and confirm your entry. Confirm warning messages that may be displayed and save your planned independent requirements. 2-4

A 1*3"1%4+5"+ is received in Sales and Distribution. Now act as if you were the sales employee and create the following sales order for the finished product T-F10##: Menu path: !"#$%&$'%(!()*+,%(*-.(/$%&0$12&$"-(!()*+,%(!(30.,0(!(40,*&,( ( Data: Values: Order type Sales organization Distribution channel Division % Sold-to party Purch.order no. Req.delivery date Material Quantity % >*?" the sales order.

2-5

67 8---% 8--% 8898 ,,-:: 6;"15*)%/!%$&4%&""'1 6<=8-:: 8--%./"0"1%

Plan the BOM structure of the PC in an @AB%+;!: Menu path: '/0(*.("*1!123/%4".(/)1!15621!12-7))()0181!()0-$9:.$;<154-.(9'$=$Use the following settings: Material 6<=8-:: Plant 8C-Further settings CD%ED%8D%8D%8% % Start the MRP run by choosing 5-&,0 twice.% % Note: Multi-level planning ensures that secondary requirements are also created for lower BOM hierarchy levels.%

ÂŠ SAP AG

TERP10

23-6

2-6

Use the stock/requirements list for the finished product !"#$%&& in '()*+,$-%%,to interpret the results: Menu path: !"#$%&$'%(!()*"+,'&$"-(!(./)(!(0123,2&$"-%(!(4&"'56/78,$*797-&%(!$%&! ! Why is the plant stock for the material not included? ____________________________________________________________

2-7

Use the stock/requirements list for assembly !".$%&& in '()*+,$-%% to interpret the results: Menu path: !"#$%&$'%(!()*"+,'&$"-(!(./)(!(0123,2&$"-%(!(4&"'56/78,$*797-&%(!$%&

2-8

Double-click a planned order to display the /0+)1(,/)+). Why are there no pushbuttons to convert the planned order to a production order? ____________________________________________________________ ____________________________________________________________

ÂŠ SAP AG

TERP10

23-7

TERP10

23-8

!"#$%&'#'( )*&+(

,#-#+&+&.#(/0*120%+1$&*3(

45-&%6( 780**&*3(9&*#(950:&*3(( At the conclusion of these exercises, you will be able to: â&#x20AC;˘ Assign production quantities to production lines, taking capacity into account. The production quantities either originate from MRP or they were created manually and assigned to the production lines in the planning table. For the final assembly of your PC T-F10## and for the assembly of the motherboard T-B10##, there is one production line respectively. After the MRP and production planning in the previous exercise, the basic dates as to quantities and periods have been determined. As the production planner, assign the quantities to the relevant production line. 3-1

Use the -80**&*3(+0;8#(25$($#-#+&+&.#(<0*120%+1$&*3 from the repetitive manufacturing planning menu to assign the planned orders to the production lines, taking available capacities into account. Call up the planning table, enter -80*+(=>?? and select by -$5:1%+&5*(8&*#. First, enter the final assembly line 4@9=AA. Then choose !"#$$%$&'(#)"*. Familiarize yourself with the period-based display of quantity and capacity data in the planning table. Fields that are ready for input are shown in white, display fields are gray as usual.

3-2

Double-click the quantity in the planning table section that is ready for input to display the detail data for the planned order. Which 5$:#$(+B-# is assigned (F4 help)? ___________________________________________________________

3-3

Switch on the 0''&3*<#*+(<5:# for the quantities not yet assigned in the planning table section that is ready for input by choosing the corresponding pushbutton. Assign the quantity not yet assigned to the final assembly line. Note: You cannot yet assign the planned orders for the planned quantities. The reason for this is the planning strategy !"#$$%$&'(%)*+,)'-%$#"'#../01"2 used. In this strategy, final assembly is only allowed when sales orders are received. In this case, the planning quantities only serve to create the relevant secondary requirements (which, however, are planned using a make-to-stock strategy and therefore can be produced without a sales order).

ÂŠ SAP AG

TERP10

23-9

3-4

Double-click the quantity you just assigned. Which !"#$"%&'($ is now assigned (F4 help)? ____________________________________________________________

3-5

Look at the )*(*)+&'%#*&*. Does the production line reach full capacity through the planned order in the relevant time interval or is there still available capacity for further orders in the same period? ____________________________________________________________

3-6

Save the line loading planning for the finished product and do exercise 3-1-3 for assembly production (use ,+-$%./0122, (,*-&%3455 to access the planning table). Why does the quantity that was already available at the beginning (plant stock) reduce the oldest planned order? ____________________________________________________________ ____________________________________________________________ Save the line loading planning for the assemblies. Note:% Since there is only one production line for final assembly and one for assembly production, you could also use *,&$"-*&+6$%7$,$)&+!- (material master, !"#$%view, alternative selection indicator = 2) to plan line loading and, if required, check the results in the planning table afterwards.

3-7

ÂŠ SAP AG

8(&+!-*,: Create a planned order 9*-:*,,' in the planning table. To do so, access the planning table (line T-L3##, plant 1200) and use the function keys right at the bottom of the planning table (not the scrollbar!) to scroll to the date .!#*'%;%3% 9!-&<. Enter a quantity of 155%(+$)$7 on line ./0122 and choose &'()* to confirm. You have manually created a planned order that can be used for production in this form. Double-check this in the planned order details. However, do not save.

TERP10

23-10

!"#$%&'#'( )*&+,( -#.#+&+&/#(01*231%+2$&*4( 56.&%,( 01+#$&17(8+14&*4(1*9(:1%;372'<( At the conclusion of these exercises, you will be able to: • Use the pull list to stage components at your production line • Carry out quantity- and period-based backflushing in repetitive manufacturing For assembly production of motherboard T-B10##, you want to check for missing components in the production storage location PL03 and use stock transfer measures to '+14#(=&''&*4(%6=.6*#*+' for a certain production period. After a production section has been completed, the quantity produced is >1%;372'<#9 in the system. Both tasks are within the supervisor’s or production scheduler’s area of responsibility, whose roles you will be playing during the following exercise. 4-1

Here, you use the pull list to execute the stock transfer from the central warehouse to the production line. Perform %6=.6*#*+('+14&*4(at assembly production line TL3##. 4-1-1 Call up the .277(7&'+(from the !"#"$%$%&"'()*+,)-$+.%*/ menu. Staging is performed for line T-L3## in plant 1200 for all requirements that are received until Tuesday in two weeks. In this example, material staging is performed at '+6$14#(76%1+&6*(7#/#7 (note that the pull list supports further staging types: using the Warehouse Management System or by event-driven KANBAN) by stock transfer from the central warehouse 0001 to the production storage location PL03. Some steps in the pull list can be carried out 12+6=1+&%177?. Make the following 476>17('#++&*4': 0%)12/'-2*$.21 tab:

Field name

Value

Create replenishment proposals Execute batch/stock determination Stage replenishment proposals Post replenishment elements Print replenishment elements

@2+6=1+&%177? @2+6=1+&%177? A*(9&1764 A*(9&1764 A*(9&1764

Execute the report and note the status bar.

TERP10

23-11

4-1-2 Go to the pull list. Interpret the results of the automated steps: For which !"#$%&"'( have planned requirements caused missing parts until Tuesday in two weeks and how big are they? ______________________________________________________ 4-1-3 For which storage location are there !&((&)*+,-")#&#&$(? ______________________________________________________ 4-1-4 At which storage location has the system found a %$.'$)&(/!$)# ,-")#&#0? ______________________________________________________ 4-1-5 Can the !"#$%&'& missing quantity be covered from it? ______________________________________________________ 4-1-6 You accept the system proposal. Trigger material staging for the relevant components from warehouse 0001 to production storage location PL03 by choosing !"#$%. 4-1-7 Caution! Material staging (here by means of stock transfer) is not carried out until you save the pull list. If you need a $()*'"+',"-,'.&,%)/' for the physical stock transfer, we recommend printing it before you save (0+%%,%)/',111, 0()*'). 2"3$. 4-1-8 Check the stock transfer posting in the !$(("*$+'4* for the pull list (separate transaction). 4-2

After a production unit that was predefined with regard to time and quantity and in which you produced 90 motherboards on line T-L3## has been completed, you are to backflush the quantity produced in the system. 4-2-1 First, create a ($54)6+($((&4) of the planning table for repetitive manufacturing (access by selection production line T-L3##, plant 1200). 4-2-2 In the first session, 7"589'-(/ :;+.&$5$( of the motherboard material T-B10## produced on line T-L3## in plant 1200. To do so, enter the data on the backflush transaction screen. You can find it in the 12!3-%+/. menu for repetitive manufacturing. Then choose &'(")*+",)-'..%-"+'/. 4-2-3 From the following screen, explain which components of assembly T-B10## were 7"589'-(/$6 on the line but do not exit this display: ______________________________________________________ ______________________________________________________ ______________________________________________________

ÂŠ SAP AG

TERP10

23-12

4-2-4 Due to a !"#$%&#'()*"+"#! of a machine, you needed ,-.)$/012 to produce 90 pieces instead of 3 hours as specified in the production rate in the routing (30 pieces per hour). To correct this, choose !"#$%&'%"#()(#(*+. On the following screen, select the only line offered and confirm. On the next screen, choose the ,-./0(1* field under !"#()(#(*+ and overwrite the planned value under 2$--*3#'#.'2.34(-1 with the actual value of 3.5 h. Choose !"#$% to confirm and save. 4-2-5 Go to the 2"#/%*)2"22&/% (planning table) and look at the quantities on the line while pressing F5 (= &'()#$). How have the planned quantities changed? ______________________________________________________

ÂŠ SAP AG

TERP10

23-13

TERP10

23-14

!"#$%&"'() *'&%+) ,-.-%&%&/-)01'$213%$4&'5) 6".&3+) 01(%-4)71%1) ) 1-1

Logistics master data: !"#$%&'($)"*$+%&'"" !",-#"" !"./0%(12"" !"3/'4"5&1%&'"6)(1&7

1-2

!"#$%&'($"))*''$')+**,-$./01'21)'$!$#+/34)21/,$!$5&'2*+$6&2&$!$5&2*+1&7$ 5&'2*+$!$5&2*+1&7$!$89&,0*$!$:;;*31&2*7()

Material View Plant

689:;<< 0,=> :?;;)

The three settings are: 1)),-.-%&%&/-)@1'$213%$4&'5)&'A&31%"4 2) ,B0).4"2&#3) =4"A$3%&"')/-4(&"') 1-2-1 On the production version detail view, choose 89&54 in the top right-hand corner. The consistency check has the following results: BOM and routing exist. There are no error messages. Exit the screen by choosing 8$15&). 1-2-2 On the detail screen, you can find out that production version 0001 contains production line 68C:<<. 1-2-3 The number varies. The 54"$.)3"$'%-4 is also displayed on the production version detail screen. You can find it under #7&,,1,0$3&2& in the <&2*=>&'*3$ ?7&,,1,0"line. 1-3

!"#$%&'($"))*''$')+**,-$./01'21)'$!$#+/34)21/,$!$5&'2*+$6&2&$!$@177'$/A$ 5&2*+1&7$!$@177$/A$5&2*+1&7$!$5&2*+1&7$@B5$!$61'?7&() Material Plant Usage)

689:;<< :?;;) :

The assembly indicator "'; is set for D BOM items.

ÂŠ SAP AG

TERP10

23-15

1-4

!"#$%&'($"))*''$')+**,-$./01'21)'$!$#+/34)21/,$!$5&'2*+$6&2&$!$7/421,0'$!$ 7/421,0'$!$7&2*$7/421,0'$!$61'89&(! Material Plant Key date

"#$%&'' %(&&! ")*+,!

1-4-1! →!"#$%!"&'$()*!+,%-,(%. or "%$'-) "-)!routings exist (two group counters). 1-4-2 In the routing overview, select the line with group counter 1 and choose +/%-#$(&)0. !

What is special is the fact that there is only one

1-4-3 operation that contains the (entire) line "#.%'' as the work center and the production rate (/&!012324!025!6)75). 1-4-4 Choose 1&$&!→!2%#3%-!&,%-,(%.. !

In the routing overview, select the line with group counter 2 and choose +/%-#$(&)0.

The work center used in the second routing is "#.(''. (Note: we will not produce anything on this work center in the following exercises.) 1-4-5 In the routing overview, select a line and choose :*&3*+. The group counter is the same as that in exercise 1-3-3. 1-4-6 Production version 0001 only allows production according to the routing with 85)70!3)79:25!% since the group counter is taken over to the production version for a more detailed specification of the routing.

1-5

!"#$%&'($"))*''$')+**,-$./01'21)'$!$#+/34)21/,$!$7*8*2121;*$5&,4<&)24+1,0$!$ 5&'2*+$6&2&$!$#+/34)2$=/'2$=/99*)2/+$!$#+/)*''$#+/34)2$=/'2$=/99*)2/+! Material Plant

"#$%&'' %(&&!

Select material T-F10## in the left part of the screen. Two product cost collectors already exist. They are assigned to the material by means of the production version (one product cost collector per production version).

TERP10

23-16

!"#$%&"'() *'&%+) ,-.-%&%&/-)01'$213%$4&'5) 6".&3+) 7'%-541%&"')8&%9):4";$3%&"'):#1''&'5)1';)0,:))

2-1

!"#$%&'($"))*''$')+**,-$./01'21)'$!$#+/34)21/,$!$5&'2*+$6&2&$!$5&2*+1&7$ 5&'2*+$!$5&2*+1&7$!$61'87&($!$61'87&($94++*,2) Material Plant

6<=>?@@ >A??)

Strategy 50 (Planning without final assembly) has been defined. 2-2

!"#$%&'($"))*''$')+**,-$./01'21)'$!$#+/34)21/,$!$5&'2*+$6&2&$!$5&2*+1&7$ 5&'2*+$!$5&2*+1&7$!$61'87&($!$61'87&($94++*,2) 1) Check whether the :*8*2121;*$5&,4<&)24+1,0)indicator has been set on the 5:#= view for both materials. It has been set. 2) Check the .4";$3%&"')/-4(&"' for both materials. Has the !"#"$%"&indicator been set? Answer: B-(.

2-3

!"#$%&'($"))*''$')+**,-$./01'21)'$!$#+/34)21/,$!$#+/34)21/,$#7&,,1,0$!$ 6*>&,3$5&,&0*>*,2$!$#7&,,*3$?,3*8*,3*,2$:*@41+*>*,2'$!$9+*&2*) – For the procedure, see the exercise. No solution required. –

2-4

!"#$%&'($"))*''$')+**,-$./01'21)'$!$!&7*'$&,3$61'2+1A421/,$!$!&7*'$!$B+3*+$!$ 9+*&2*) – For the procedure, see the exercise. No solution required. –

2-5

!"#$%&'($"))*''$')+**,-$./01'21)'$!$#+/34)21/,$!$5:#$!$#7&,,1,0$!$!1,07*C ?2*>D$54721C.*;*7) – For the procedure, see the exercise. No solution required. –

TERP10

23-17

2-6

!"#$%&'($"))*''$')+**,-$./01'21)'$!$#+/34)21/,$!$56#$!$%7&84&21/,'$!$ !2/)9:6*;41+*<*,2'$.1'2! Material Plant

"#$%&'' %(&&!

The plant stock as well as an individual customer segment for the sales order and a planning segment are displayed. There are planned orders for the planned independent requirements in the planning section. One planned independent requirement has been partly consumed by the sales order and results in a planned order in the individual customer segment due to the MRP run. The plant stock and the sales order stock must !"#"$ be consumed by each other. Make-to-order production always involves separate, sales order-specific inventory management. 2-7

!"#$%&'($"))*''$')+**,-$./01'21)'$!$#+/34)21/,$!$56#$!$%7&84&21/,'$!$ !2/)9:6*;41+*<*,2'$.1'2! Material Plant

"#)%&'' %(&&!

Assembly T-B10## is produced in a make-to-stock strategy, which is why the plant stock is considered in the consumption. The secondary requirements that were created due to the planned independent requirements as well as the relevant planned orders are displayed. 2-8

ÂŠ SAP AG

Materials T-B10## and T-F10## are pure *+,+-.-./+!0123415-3*.26!01-+*.178 (%"&"'('(#")*+!,-+.',$(!/ indicator is set in the material master). The planned orders can be used for production and can therefore !0' be converted to production orders.

TERP10

23-18

!"#$%&"'() *'&%+) ,-.-%&%&/-)01'$213%$4&'5) 6".&3+) 7#1''&'5)8&'-)8"19&'5))

3-1

!"#$%&'($"))*''$')+**,-$./01'21)'$!$#+/34)21/,$!$5*6*21217*$8&,49&)24+1,0$:$ #;&,,1,0$:$#;&,,1,0$<&=;*$!$>?&,0*$8/3*) To access the planning table, enter: Plant Selection

:;<< 74"9$3%&"')#&'-)6=8:>>

Choose #;&,,1,0$2&=;*. 3-2

Double-click a planned order in the planning table section that is ready for input (shown in white). The planned order has order type ?@)(Individual customer order).

3-3

Activate the 1((&5'A-'%)A"9- for the quantities not yet assigned in the planning table section that is ready for input by selecting the @/2$(*2$&''10,*3)line in the bottom !"#$%&"'()"#" table (to select, click on the button at the beginning of the line) and then choosing the .$(BC$%%"')9&(.#1D&'5)1)%4$3E. A symbol appears at the start of the line, signifying that you are in assignment mode for this line. Read the quantity in the *+#(,$#("--&./$) section and enter it in the field on the production line that belongs to the same period, and confirm. @-13%&/1%- the assignment mode again by choosing the corresponding pushbutton.

3-4

Double-click a planned order that has been assigned to the production line in the planning table. The planned order has order type 7F (Run schedule quantity).

3-5

By dispatching a planned order on production line T-L1##, the line only reaches a comparatively low capacity load (see planning table: 31.13&%D)91%1 in the row for production line T-L1##). This means, you could theoretically dispatch further quantities for the same period. Note: The capacity data is not available on the same day as the production quantities since the 01"/#&#&$- are determined to the day according to availability while the 2"3"2&#,('+") of the production line is determined to the hour and minute according to the production date. You can change the display from within the planning table by choosing A1*B$!$ 5*9*+*,)*$C&2*'$!$#+/34)21/,$C&2*'.

ÂŠ SAP AG

TERP10

23-19

3-6

!"#$ the line loading planning for the finished product T-F10##. !"#$%&'($"))*''$')+**,-$./01'21)'$!$#+/34)21/,$!$5*6*21217*$8&,49&)24+1,0$:$ #;&,,1,0$:$#;&,,1,0$<&=;*$!$>?&,0*$8/3*% To access the planning table, enter: Plant Selection

&'(( )*+,-./0+1%201$%345677

Choose #;&,,1,0$2&=;*. Switch on the "88091:$1/%:+,$ for the quantities not yet assigned in the planning table section that is ready for input by selecting the !"#$%&#$'(()*+&, line and then choosing the pushbutton showing a truck. Read the quantities in the !"#$%&#$'(()*+&, section and enter them in the field on the production line that belongs to the same period, and confirm. !;0/.<%+== the assignment mode again and save. The T-B10## (which does not belong to any sales order) is on stock; the existing stock can be used for production planning. 3-7

– For the procedure, see the exercise. No solution required. – %

TERP10

23-20

!"#$%&"'() *'&%+) ,-.-%&%&/-)01'$213%$4&'5) 6".&3+) 01%-4&1#)!%15&'5)1'7)) 81392#$(:&'5)

4-1

!"#$%&'($"))*''$')+**,-$./01'21)'$!$#+/34)21/,$!$5*6*21217*$8&,49&)24+1,0$:$ 8&2*+1&;$!2&01,0) 4-1-1 #4;;$.1'2$<$=+100*+$5*6;*,1'>?*,2) Staging type Plant Selection period

!%"415-)#"31%&"')#-/-# ;<== 6$-(71>)&')%?")?--9(

On the !"#$$%&'()&%) tab, choose: Production line

6@ABCC)

Choose @;/A&;$'*221,0'. On the B1&;/0$)/,2+/; tab, choose:

)

Create replenishment proposals Execute batch/stock determination Stage replenishment proposals Post replenishment elements Print replenishment elements

D$%"E1%&31##> D$%"E1%&31##> F')7&1#"5 F')7&1#"5 F')7&1#"5

Confirm your entries and execute the report.

)

4-1-2 Due to the planned requirements, there are E&((&'5)G$1'%&%&-( for material TT6## until Tuesday in two weeks. The system automatically created a replenishment proposal and determined stock for component T-T6## in storage location 0001. The pull list shows how big the missing quantity is. 4-1-3 There are missing quantities at the .4"7$3%&"')(%"415-)#"31%&"')HA=B, where the components for assembly production are to be staged. 4-1-4 The replenishment quantity was found in central warehouse 0001. 4-1-5 Yes, the staging quantity is equal to the missing quantity. 4-1-6 – For the procedure, see the exercise. No solution required. – 4-1-7 – For the procedure, see the exercise. No solution required. – 4-1-8 !!!./0) $

Call up the log in the *#+%),#"'-+#.,$. menu, enter /(&#0 as the from-date, and choose 12%34+%. The stock transfer was successfully posted in the system.

TERP10

23-21

4-2

!"#$%&'($"))*''$')+**,-$./01'21)'$!$#+/34)21/,$!$5*6*21217*$8&,49&)24+1,0$:$ ;&)<9=4'>$!$5%8$;&)<9=4'>! 4-2-1 Choose !"#$%&'!'()%*$%'#%##+,- to create another session. In the new session, choose: !"#$%&'($"))*''$screen: ./01'21)'$!$#+/34)21/,$!$5*6*21217*$ 8&,49&)24+1,0$:$#=&,,1,0$:$#=&,,1,0$?&@=*$!$A>&,0*$8/3* To access the planning table, enter: Plant Selection

"#$$ %&'()*+,'-!.,-/!012344

Choose #=&,,1,0$2&@=*. 4-2-2 Enter the following data on the ;&)<9=4'>$2+&,'&)21/, screen: Backflush type Backflush qty Material Plant Prod.version *)

566/78.9!8:*;<.)6=! >$!?,/*/6 01@"$44 "#$$ $$$"*)

The production version .,&/)+#%# the production on line T-L3##.

Choose #/'2$B12>$)/++*)21/,. 4-2-3 The *)&&/-+!@AB!was exploded during the backflush. The system determined the materials to be backflushed in the BOM explosion. The all or nothing principle applies, which means that all four materials displayed are backflushed. 4-2-4 – For the procedure, see the exercise. No solution required. – 4-2-5 Go to the second session (planning table) and choose F5 (Reaccess planning table). The oldest planned order quantity or quantities are &/()*/( according to the backflush quantity. Explanation: For demonstration purposes, the backflush was made with a date (today) that is 0%1,)% the actual production dates. The backflush quantity is therefore interpreted as 2,3%)4/),56.$+,-7 that reduces later planned orders accordingly (oldest planned orders first).

TERP10

23-22

!""#$%&'()*(+,-./,#0#$1(23.4#

2-$1#$16* ! !%%&1&-$54(2-/,6#(74&%#6*(+,-./,#0#$1(23.4#

 SAP AG 2002

TERP10

24-1

!""#$%&'()*(+,-./,#0#$1(23.4#*(5$&1(678#.1&9#:

!1(1>#(.-$.4/:&-$(-<(1>&:(/$&1?(3-/(@&44(7#(=74#(1-* ! ;%#$1&<3(=%%&1&-$=4(",-./,#0#$1(.3.4#(</$.1&-$=4&13

ďŁŠ SAP AG 2006

This topic covers the basics of manufacturing products using process orders. The LO310 course covers this topic in further detail.

ÂŠ SAP AG

TERP10

24-2

5-)%"#-*&4-*8-)#'(&!"'$%28"%.

5-)%"#-*&4-*8-)#'(

!"#$%&$'()"'* +#(&,-)%"#-*&,-.)%"/

010 1)-(2-"2&3"#$%

040 5'6#(7&-6%"-7%&3"#$%

 SAP AG 2006

You set the material valuation procedure you want to use in the accounting view of the material master record. In the R/3 System, you can carry out material valuation using the standard price procedure or moving average price procedure.

In the standard price procedure (price control “S”), the system carries out all stock postings at a price defined in the material master. Variances are posted to price difference accounts.

In the moving average price procedure (price control “V”), the system valuates goods receipts with the purchase order price and goods issues with the current moving average price. The system automatically calculates the latter upon every goods movement by dividing the total value by the total stock quantity. Differences between the purchase order price and the invoice are posted directly to the relevant stock account if there is sufficient stock coverage.

TERP10

24-3

)%"*+%,-.50121

)%"*+%,-./0121 !"#$$%&

'$("#$$%&

4$+0*/% 100 pcs Freight

4$+0*/% EUR 1000 EUR 200 EUR 1200

100 pcs Freight

EUR 1000 EUR 50 EUR 1050

ďŁŠ SAP AG 2002

The R/3 System differentiates between planned and unplanned delivery costs.

You arrange planned delivery costs in advance with the vendor, a carrier, or the customs office and enter them when creating the purchase order. At goods receipt, provision accounts are posted, which are then cleared when the invoice is received.

Unplanned delivery costs are delivery costs you do not know about when you are creating the purchase order. You do not enter these until the you receive the invoice.

The advantage of planned delivery costs is that they are included in the valuation of a material at goods receipt or, for purchase orders with account assignment, the system can debit the account assignment object. The system only carries out subsequent debits at invoice receipt if the delivery costs in the invoice differ from those planned.

ÂŠ SAP AG

TERP10

24-4

89"#:*3$-7;+4"0*$.;2*;

.73012*$34* 0503*6 <

< !"#$%&$&''(

)*+$,&$&''(

-. CCtr 24,000.00 4,000.00

Validity period Jan 01 98 Dec 31 98

/#012*$34*$ 0503*6

CCtr 18,000.00 CCtr 51,000.00 CCtr 31,000.00 10,000.00

ďŁŠ SAP AG 2006

You can use blanket purchase orders to procure consumable materials or services for which it is not worth creating a separate purchase order for each procurement transaction.

Blanket purchase orders are usually valid for a longer period of time. You can directly post the invoices for the materials and services procured for this blanket purchase order.

ÂŠ SAP AG

TERP10

24-5

234554+/6:,1474)(14,+6(+&6;,,&<6=')'451

234554+/6+,1474)(14,+ $%&'% ()*+,-.'&/'0'+1

!8 9,+74%0(14,+6),+1%,.66666666

ďŁŠ SAP AG 2006

If you expect an order acknowledgement for your purchase order, you can set a confirmation control key in the purchase order item. You can configure which type of order acknowledgements you expect to receive and whether these are relevant to Materials Planning and goods receipt.

You configure your system so that a particular type of order acknowledgement is referenced (e.g. a shipping notification) at goods receipt. The goods receipt cannot be posted without an order acknowledgement.

You can post a goods receipt with reference to a shipping notification or purchase order. If you enter the goods receipt with reference to the purchase order, the system recognizes from the confirmation control key whether the one or more order acknowledgements are required, and whether acknowledgements have already been entered in the system. You can only post the goods receipt for the quantities on the acknowledgement.

ÂŠ SAP AG

TERP10

24-6

;<2(02*"$,5")"+9*,'"**("8"#*

!"#$%&

'"(")*+%#,-)&""#.

!"#$%& /0&)12-",%&$"&

7%892#:

/%-*+#3,$2*",45 /(2#*6*1"&-

 SAP AG 2002

You can choose transactions for settlement according to the following criteria: •

Posting date of the goods receipts

•

Vendor

•

Company code

•

Purchase order and purchase order items

•

Plant

You can use the following criteria to delimit the invoice documents created: •

An invoice document per vendor

•

An invoice document per purchase order

•

An invoice document per purchase order item

•

An invoice document per goods receipt document

TERP10

24-7

!""#$%&'()*(+,-./,#0#$1(23.4#*(5$&1(6/007,3(

:-/(7,#($-;(7<4#(1-* ! 8%#$1&93(7%%&1&-$74(",-./,#0#$1(.3.4#(9/$.1&-$74&13

ďŁŠ SAP AG 2002

This topic covers the basics of manufacturing products using process orders. The LO310 course covers this topic in further detail.

ÂŠ SAP AG

TERP10

24-8

())%#*+,-.'-/012+$3-41#15%6%#$

!"#$%#$&' ! 70#8$+"#&-+#-/012+$3-41#15%6%#$ ! 9:%;:+%<-"=-/012+$3-41#15%6%#$-+#-$>%?"5+&$+8&-@0))23-!>1+#

 SAP AG 2004

TERP10

25-1

!""#$%&'()*(+,-.&/0(1-$-2#3#$/*(4$&/(567#8/&9#:

!/(/=#(8?$8.,:&?$(?>(/=&:(,$&/A(0?,(@&..(6#(-6.#( /?* ! ;#:8<&6#(/=#(>,$8/&?$:(?>(+,-.&/0(1-$-2#3#$/( ! 4$%#<:/-$%(/=#(,:#(?>(+,-.&/0(1-$-2#3#$/(&$(/=#( %&>>#<#$/("<?8#::#:(@&/=&$(-(8?3"-$0

 SAP AG 2004

TERP10

25-2

!"#$%&'#()'*)+",-&%.)/,#,0121#%3)4'5&$) 6781$%&91(

=%)%<1)$'#$-"(&'#)'*)%<&()%'5&$>).'")?&--)71),7-1) %'3 ! :1($;&71)%<1)*"#$%&'#()'*)+",-&%.)/,#,0121#%

 SAP AG 2004

TERP10

25-3

+)#&%"'(,#.#/6=6."(51=91.6."4

+)#&%"'(-&#..%./ !"#$%&%"'(!")*'

:64"(;<)%9=6." ,#.#/6=6."

+)#&%"'(8.4963"%1.

+)#&%"'(567"%2%3#"64 +)#&%"'(51."71& +)#&%"'(01"%2%3#"%1.4  SAP AG 2004

The QM component is divided into the following subcomponents: •

Quality Planning

•

Quality Inspection

•

Quality Certificates

•

Quality Notifications

•

Quality Control

•

Test equipment management

•

Stability Study

TERP10

25-4

A"*0&%1*-(%*(!"#$%&'(:#*#+/9/*& ;>)(;'-&/9 !

!"#$%&'()$#**%*+

!"#$%&'(,*-./0&%1*

!"#$%&'(2/3&%4%0#&/-

!"#$%&'(51&%4%0#&%1*-

!"#$%&'(21*&31$

6/-&(78"%.9/*&(:#*#+/9/*&

;&#<%$%&'(;&"='

9';>)(;2:

9';>)()?:( !"#$%&'( :#*#+/9/*&

9';>)()?:(

9';>)( 6/0@*1$1+' ďŁŠ SAP AG 2004

The functions of the QM component cover the classic quality management tasks such as quality planning, quality inspection, and quality control, as well as supplementary functions.

ÂŠ SAP AG

TERP10

25-5

!"#$%&'()$#**%*+C(D0&%E%&%/-

!"#$%&'()$#**%*+ !"#$%&'(,*-./0&%1*

23/#&%*+(#*=(9#*#+%*+(&>/( 9#-&/3(=#&#(&>#&(%-(3/8"%3/=( ?#91*+(1&>/3(%&/9-@(&1(.$#*(#*=( /A/0"&/(8"#$%&'(%*-./0&%1*-B

!"#$%&'(2/3&%4%0#&/!"#$%&'(51&%4%0#&%1*!"#$%&'(21*&31$ 6/-&(78"%.9/*&(:#*#+/9/*& ;&#<%$%&'(;&"='

 SAP AG 2004

You use "#$%&'(!)%$**&*+ for the following: •

General master data (for example, material master, batch data, vendor master records)

•

QM specific master data (for example, master inspection characteristics, inspection methods, sampling procedures)

•

Inspection planning functions (for example, inspection plan, material specification)

TERP10

25-6

!"#$%&'(,*-./0&%1*A(B0&%C%&%/-

,=/*&%4'%*+(>?/&?/3(&?/( %*-./0&/=("*%&-(4"$4%$$(&?/( .3/=/4%*/=(8"#$%&'( 3/8"%3/9/*&-@

! !"#$%&'()$#**%*+ ! !"#$%&'(,*-./0&%1* ! !"#$%&'(2/3&%4%0#&/! !"#$%&'(51&%4%0#&%1*! !"#$%&'(21*&31$ ! 6/-&(78"%.9/*&(:#*#+/9/*& ! ;&#<%$%&'(;&"='

 SAP AG 2004

"#$%&'(!&)*+,-'&.)!covers the following functions: •

Inspection lot processing (from creation to completion)

•

Results recording

•

Defects recording

•

Sample management

•

Interfaces to subsystems (such as QM-IDI, measurement data transfer by using a keyboard wedge)

TERP10

25-7

3-./%$'*!"#$%&%4.$"5C*D4$%9%$%"5

! 3-./%$'*;/.((%() ! 3-./%$'*<(58"4$%0( ! 3-./%$'*!"#$%&%4.$"5

!"#$%&'%()*$+"*,-./%$'*0&*.* 1.$"#%./2 3-./%$'*4"#$%&%4.$"5*40($.%(* $"6$57*58"4%&%4.$%0(*9./-"57* .(:*%(58"4$%0(*#"5-/$52

! 3-./%$'*=0$%&%4.$%0(5 ! 3-./%$'*!0($#0/ ! >"5$*?,-%81"($*@.(.)"1"($ ! A$.B%/%$'*A$-:'

 SAP AG 2004

The "#$%&'(!)*+'&,&)$'*- function allows you to create and monitor certificates to confirm the quality of a product. You can send quality certificates over the Internet. You can create the following certificates: •

Certificate of conformity

•

Works test certificate

•

Certificate of analysis

•

etc.

Quality certificates can, for example, be used for goods receipts and for goods issues.

TERP10

25-8

:5+/'.4*?$.'>'#+.'$(-D*E#.'8'.'"-

!"#$%&'()*+(&*,%$#"--'()* '(."%(+/ $%*"0."%(+/ ,%$1/"2-* .3+.*+%"*,%'2+%'/4*#+5-"&*14* ,$$%675+/'.4*)$$&-*$%*-"%8'#"-9

! :5+/'.4*;/+(('() ! :5+/'.4*<(-,"#.'$( ! :5+/'.4*="%.'>'#+."! :5+/'.4*?$.'>'#+.'$(! :5+/'.4*=$(.%$/ ! @"-.*A75',2"(.*B+(+)"2"(. ! C.+1'/'.4*C.5&4

 SAP AG 2004

The "#$%&'(!)*'&+&,$'&*)-!function covers the recording and processing of quality problems (internal or external) and includes: •

Defect analysis

•

Documentation

•

Priority

•

Entry of the partner concerned

•

Costs recording

•

etc.

Examples of quality notifications: •

Complaint against a vendor

•

Customer complaint

•

Internal problem notification

•

Notification concerning problems in production

TERP10

25-9

;/,$('8*=.&'-.$B*C3'(+('(%0

;/,$('8*<$,&&(&)

;/,$('8*!&0#%3'(.&

;/,$('8*=%-'(6(3,'%0

;/,$('8*>.'(6(3,'(.&0

;/,$('8*=.&'-.$

?%0'*@7/(#"%&'*A,&,)%"%&'

!"#$%"%&'(&)*+,-(./0* #-%+%&'(+%1*".&('.-(&)*,&2* 3.--%3'(+%*,3'(+('(%04 5#%3(6(3,'(.&0*6-."*7/,$('8* #$,&&(&)*,&2*%+,$/,'(.&0* 6-."*7/,$('8*(&0#%3'(.&0*,&2* 7/,$('8*&.'(6(3,'(.&0*6.-"*'9%* :,0(0*6.-*7/,$('8*3.&'-.$4

!5',:($('8*5'/28

 SAP AG 2004

"#$%&'(!)*+',*%!covers the following functions: •

Dynamic modification of the inspection scope

•

Statistical process control (SPC; control charts, results history)

•

Quality scores (cp value, cpk value)

•

Vendor Evaluation

•

Quality-Related Costs

•

Evaluations

TERP10

25-10

6/-&(78"%.9/*&(:#*#+/9/*&@(A0&%B%&%/-

:#*#+%*+(9#-&/3(=#&#(#-(>/$$( #-(.$#**%*+(#*=(.310/--%*+( 0#$%<3#&%1*(%*-./0&%1*-(413(&/-&( /8"%.9/*&?

! !"#$%&'()$#**%*+ ! !"#$%&'(,*-./0&%1* ! !"#$%&'(2/3&%4%0#&/! !"#$%&'(51&%4%0#&%1*! !"#$%&'(21*&31$ ! 6/-&(78"%.9/*&(:#*#+/9/*& ! ;&#<%$%&'(;&"='

 SAP AG 2004

The "#$" #%&'()#*"!)+*+,#)#*"!function covers: •

Creation and management of test equipment master data

•

Calibration planning functions (for example, definition of calibration cycles)

•

Calibration inspection functions (for example, inspection specifications)

•

Calibration inspection processing

•

Test equipment tracking

Test equipment management uses functions from the plant maintenance area.

TERP10

25-11

;&#<%$%&'(;&"='

! !"#$%&'()$#**%*+ ! !"#$%&'(,*-./0&%1*

:#*#+/9/*&(14(<#-%0(=#&#>(#-( ?/$$(#-(&@/(.$#**%*+(#*=( /A/0"&%1*(14(-&#<%$%&'(-&"=%/-B(

! !"#$%&'(2/3&%4%0#&/! !"#$%&'(51&%4%0#&%1*! !"#$%&'(21*&31$ ! 6/-&(78"%.9/*&(:#*#+/9/*& ! ;&#<%$%&'(;&"='

 SAP AG 2004

The "#$%&'&#(!"#)*(!function covers: •

Creation and management of basic data (material, batch, bills of material, inspection characteristics, catalogs)

•

Functions for planning of stability studies (for example, testing schedule, inspection strategies, scheduling)

•

Functions for the execution of stability studies (for example, inspection specifications)

•

Functions for the processing of stability studies (for example, create initial sample, execute initial test, define storage conditions, scheduling, execute stability tests, remove stability samples from storage)

•

Stability history

The stability study function uses functions from the plant maintenance area.

TERP10

25-12

.#(/,0"(1$"2$3#%+0,4$5%(%6'7'(,-$8"90/$:#77%&4

!"#$%&'$(")$%*+' ,"! ;'1/&0*'$,<'$2#(/,0"(1$"2$3#%+0,4$5%(%6'7'(,

 SAP AG 2004

TERP10

25-13

!"#$"%#&'()'*+'%,'-.#'/(0%1-%21'345567'8.9%,:' ;(5%2'!<=#2-%"#1

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 SAP AG 2004

TERP10

25-14

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ďŁŠ SAP AG 2004

Different departments in a company process a product throughout its life cycle.

The procedures differ, depending on the production process (for example, production operations that are processed externally).

The integration of the quality management processes and the exchange of information between individual areas within the company form the basis for achieving customer satisfaction.

The integration of the QM component in SAP business processes allows you to process inspections (such as, goods receipt inspections, inspections during production or inspections for stock transfers and delivery), and to record data relating to product quality (such as, management of customer specifications for a product or inspection results) throughout the logistics supply chain.

ÂŠ SAP AG

TERP10

25-15

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>)?.5")&"03?0@5,.%-A0+,),*"1") SAP AG 2004

The QM component can be integrated in all areas of the logistics supply chain. Prerequisite for this is that you make the relevant Customizing settings in QM.

If QM is in use in your company and you identify poor-quality goods or services, you can suspend a process until the problem is resolved.

Examples of the influence of quality management in the logistics supply chain: •

Sales and distribution: Creation of customer-specific inspection specifications (1)

•

Material requirements planning: Availability of production resources and tools (PRTs) (2)

•

Production: Inspections during production (with integrated reference operation sets and inspection operations in the routing or master recipe) (3)

•

Materials management: Goods receipt inspections, vendor evaluation and inspection stock (4)

•

Stockholding: Inspection of stock transfers, stock monitoring (for example, of shelf-life) (5, 6)

•

Shipping: Inspection for delivery (7)

•

Service: Use of quality notifications (for example, to process complaints) (8)

TERP10

25-16

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ďŁŠ SAP AG 2004

You can store quality-relevant information for the customer/material combination (customer information record). This information can then control QM activities in sales and distribution, such as goods movements, creating certificates, etc.

On the basis of the sales order, you can also include customer-specific inspection specifications.

ÂŠ SAP AG

TERP10

25-17

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ďŁŠ SAP AG 2004

During production planning, you plan the inspection-relevant operations. These operations are taken into account for material requirements planning (for example, duration of a goods receipt inspection). The material is then available in good time for production.

If the functions for test equipment management are active, you can use them to control the release of production resources and tools.

You can display planned receipts in inspection stock in the MRP list.

ÂŠ SAP AG

TERP10

25-18

<=1()1!"#$%&'(#) *'#"+,-

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 SAP AG 2004

By integrating the QM component in the production process, you can monitor and document the quality of goods as they are produced. When a production or process order is released, an inspection lot is created automatically for an inspection during production.

The QM component provides various statistical and graphical procedures for statistical process control (SPC), such as: •

Control charts

•

Histograms

•

Key figures for process capability

The quality notification allows you to document and process any problems that occur. For example, quality notifications can be created automatically, if during an inspection you identify that the specification limit has been exceeded.

The posting of a yield from a goods receipt to the warehouse can be automated (control key in the operation, automatic milestone confirmation and backflushing). In addition, when goods are received in the warehouse, stock-relevant inspection lots can be created.

During the course of a quality inspection, you can split materials into batches and partial lots and you can define inspection points.

TERP10

25-19

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 SAP AG 2004

You require externally supplied materials to produce certain goods. If QM is active in procurement, you can use quality-related vendor/material information to control the supply relationships, for example: •

Vendor evaluation, invoice block

•

Vendor release

•

Certification monitoring (QM system valid until...)

The QM data recorded in procurement for a goods receipt provides the purchasing department with the required information to evaluate vendors. This information includes the results of the goods receipt inspection, complaints about the goods, and audit results.

If necessary, you can block the delivery of goods from a vendor as a result of the GR inspection results.

The quality information record procurement controls whether a source inspection or a goods issue inspection takes place for the vendor’s goods. If a source inspection takes place, there is no GR inspection.

If the vendor has a QM system, this information is also stored in the vendor master record (screen ’Control’). As a customer, you define your requirements for the vendor’s QM system in the material master.

If a certificate is to be sent with the delivery, this information is stored in the material master.

Complaints (complaints against a vendor) are processed using quality notifications.

TERP10

25-20

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ďŁŠ SAP AG 2004

Following a stock transfer within the company, for example a goods movement between plants or warehouses, you can use the QM functions to inspect the goods according to the required characteristics.

For a goods receipt from production into the warehouse (inspection lot origin 04), you can carry out a goods receipt inspection and subsequently release the goods.

ÂŠ SAP AG

TERP10

25-21

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ďŁŠ SAP AG 2004

QM allows you to plan and implement the monitoring of deadlines for batches of materials, for example, for goods with a shelf-life expiration date.

You define the inspections that are to take place for a material in the material master.

ÂŠ SAP AG

TERP10

25-22

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ďŁŠ SAP AG 2004

When goods are delivered, characteristics, for example those specified in the sales order, are inspected. These values, for example that have been specified in the variant configuration, can also be copied into the production order and used as inspection specifications.

If required, you can create quality certificates that contain data for the finished product or for materials in the production chain.

Customer complaints can be recorded and processed using quality notifications.

Quality certificates: The condition technique in SD controls the creation of quality certificates. You can also control the type of certificate that is to accompany the delivery and the information that is to be printed on this certificate specific to the customer or material. Certificates can be sent electronically.

ÂŠ SAP AG

TERP10

25-23

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ďŁŠ SAP AG 2004

You can record customer complaints in quality notifications and pass them on to the responsible department for further processing.

If goods are returned, you can inspect them and then analyze and document any defects and take appropriate corrective action.

ÂŠ SAP AG

TERP10

25-24

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ďŁŠ SAP AG 2004

QM processes can be triggered by different events.

Standard processes (for example, inspections during production, goods receipt inspections) are planned in advance and are triggered regularly.

Event-controlled processes occur spontaneously (such as defects in production, damaged goods at goods receipt); the problems that occur can be recorded and processed in a quality notification.

In addition, you can monitor critical values using the information system and if necessary, trigger tasks via the Workflow. The data collected in planned and event-controlled processes (such as, the number of complaints) is evaluated in the information system.

ÂŠ SAP AG

TERP10

25-25

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<&*$%/$#%+=4005>+?.)$'  SAP AG 2004

An inspection can be triggered at different stages in the logistics supply chain. This leads to the creation of an inspection lot.

Triggers can include: •

Goods movements (goods receipt, stock transfer, goods issue)

•

Orders (production orders, maintenance orders, delivery)

•

Deadline monitoring (batch monitoring)

•

Source inspections

The inspection lot forms the basis for inspection processing. It contains all the data for the inspection (such as material, order, inspection specifications, inspection lot size, quantity to be inspected, or, if required, QM order).

You record inspection results for this inspection lot.

The usage decision specifies whether the goods are accepted or rejected, based on the results of the inspection.

TERP10

25-26

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 SAP AG 2006

In procurement, the QM component has functions for managing, controlling, and processing the following objects, based on: •

Material

•

Material and vendor

•

Vendor and manufacturer

QM in Procurement •

Processes the evaluation, release, and selection of vendors (for example, release of a vendor for specific quantities, for a specific period, for a material)

•

Manages quality documents (for example, technical delivery terms)

•

Controls whether a source inspection or a goods receipt inspection is to take place

•

Processes complaints against a vendor

TERP10

25-27

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 SAP AG 2004

QM is integrated in different stages of the procurement chain (when procuring required materials).

You define automatic decision-making criteria to ensure that your company receives high-quality goods (for example, vendor evaluation, goods receipt inspection). If, for example, vendors’ goods are blocked as a result of poor quality, the system does not propose these vendors and marks them as blocked. In addition, the inspection scope can be controlled using dynamic modification, based on the quality of the delivered goods.

The quality information record procurement contains data relating to the vendor release, certificate control, certification and quality assurance agreements.

You can use a vendor/manufacturer release to ensure that a vendor only delivers goods from a specific manufacturer.

You define a certificate requirement for a material, by using an indicator in the material master.

QM at goods receipt controls, for example, whether: •

The goods are posted to inspection stock

•

Inspection lots are created at goods receipt

•

The delivery or invoice is to be blocked as a result of a complaint (such as a missing certificate)

TERP10

25-28

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ďŁŠ SAP AG 2006

In production, the QM component provides you with important information about the current quality of the manufactured goods (statistical process control) and if necessary, you can intervene with quality notifications (Workflow link) to implement corrective tasks.

QM inspection planning is integrated in the production planning functions. Inspection operations are included in the routing (production planning in discrete manufacturing) or in the master recipe (production planning in the process industry).

Inspections during production are controlled using the inspection operations that are contained in the routing or the master recipe.

ÂŠ SAP AG

TERP10

25-29

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ďŁŠ SAP AG 2004

In production, the integration of inspection specifications in the routing allows you to record QMrelevant information. The inspection operations are therefore integrated in the work processes of the production chain.

Inspections during production and inspections for external processing are triggered automatically.

The control key in the task list operation (such as routing, master recipe, inspection plan) defines whether inspection characteristics are to be used.

Inspection points allow you to repeatedly record results for the same inspection characteristic in one order. You can define the point, at which an inspection is to take place (for example, every two hours, every tenth wire basket, every 100 pieces). Inspection points can be created automatically during the order release or manually during the results recording.

If some production operations are to be processed externally, the system automatically creates a purchase requisition. You can carry out a quality inspection for the goods receipt that has been created by this purchase requisition.

You confirm the yield and scrap quantity to the production order.

Partial lots enable you to manage several different quality grades in the production process.

For production processes in the process industry, you can set the system so that approval of the inspection lot is required before the lot can be released for results recording.

ÂŠ SAP AG

TERP10

25-30

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 SAP AG 2006

The QM component inspection processing for goods issue. When the goods shipped, the QM component supplies the quality certificates to accompany the delivery.

You can process customer complaints efficiently using quality notifications.

Control of inspections for outbound deliveries is defined in the quality info record for sales: •

Definition of when the goods issue for the delivery can be posted: after the completion of the goods issue inspection, or before the goods issue inspection.

•

Definition of whether the inspections are performed by the customer – that is no inspection lot is created for the delivery item.

TERP10

25-31

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 SAP AG 2006

The QM application component supports sales and distribution processes by: •

Quality inspections for a delivery (dependent on sales organization, customer and material)

•

Quality certificates for a delivery (with reference to sales organization, customer and material)

•

Management of customer terms of delivery

Customer specifications can be used for batch determination.

In the service area, customer complaints are received and are distributed for further processing in the system, based on the nature of the problem.

TERP10

25-32

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!"#$%&$'%()*++,-(./0$1 ďŁŠ SAP AG 2006

In addition to the standard processes, there are event-controlled processes in the logistics supply chain, which are triggered when problems occur.

You record, analyze and document these problems in quality notifications and forward them to the departments responsible for further processing.

You can define follow-up actions that help resolve problems quickly.

ÂŠ SAP AG

TERP10

25-33

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The Early Warning System (EWS) in the Quality Information System (QMIS) allows you to monitor critical values. If, for example, the quality score drops below the specification limit of 70, a Workflow is automatically triggered.

The data in the Information System is updated continuously with results of the standard and eventcontrolled processes.

The monitoring process is supported by different types of analyses (for example, trends, threshold values, and so on).

If the predefined critical tolerances are exceeded, the system can automatically trigger follow-up actions (for example, sending a message to the Production Manager).

You can compare the data with preplanned scores. You can also define your own analyses based on characteristics and scores.

ÂŠ SAP AG

TERP10

25-34

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 SAP AG 2004

TERP10

25-35

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 SAP AG 2006

TERP10

25-36