ISSXPress Implementation

ISS Consulting�Nov 24-25 ,2009

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Training: Production Planning and Execution

Agenda

1. Training Approach
2. Training Data
3. PP Master Data
4. Planning and MRP
5. Shop Floor Control
6. Engineering Change Request

Training Approach

• Concept and purpose of transaction
• Ref:http://help.sap.com/saphelp_erp60_sp/helpdata/en/e1/8e51341a06084de10000009b38f83b/frameset.htm
• Demonstration for key transactions
• Questions
• Exercises

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Agenda

1. Training Approach
2. Training Data
3. PP Master Data
4. Planning and MRP
5. Shop Floor Control
6. Engineering Change Request

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Training Data

• Logins
• ID: TRAINING01 to TRAINING20
• Password: welcome or 123456 or 1234567
• Finished goods
• FANEOFA502162056 - GROW ADVANCE 1000G SGP P983 (10058635)
• FNCHSFS18L352522Z - 18L (N) CAROLIN PURE PALM OLEIN VER E/A
• FPCOM0002LTPET08 - 2L PET BOTTLE ROUND C/W Cap
• PWNI248430804389 - S26 GO NEWBORN,900G FOR AUS (AF 11719-1)
• EBSPE40100CLPN01 - 99MM NON DIMPLED SANITARY END KA 1573
• XANESGARL0101012 - 400G ABBOTT POUCH FOIL (MATT)
• Customer
• 110001
• Sales orders

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Agenda

1. Training Approach
2. Training Data
3. PP Master Data
4. Planning and MRP
5. Shop Floor Control
6. Engineering Change Request

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PP Master Data: Overview

• Work Center
• Bill of Material (BOM)
• Routing

PP Master Data: Concept

PP Master Data: Work Center

PP Master Data: Work Center

PP Master Data: Work Center

• Key Transactions:
• CR01 / 02 / 03: Create/change/display Work center

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PP Master Data: Work Center

• Questions
• Which data must be created before creating Work centers?
• Can Work center be deleted with open production orders?
• Can Work center be deleted when it is still used in routing?

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PP Master Data: Work Center

• Exercises
• Create Work Center by copying
• Delete Work Center

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PP Master Data: Bill of Material

PP Master Data: Bill of Material

PP Master Data: Bill of Material

• Key Transactions:
• CS01 / 02 / 03: Create/change/display BOM
• CS12: Multi-level BOM explosion
• CS15: Where-used list

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PP Master Data: Bill of Material

• Questions
• Question: What master data must be created before BOM?

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PP Master Data: Bill of Material

• Exercises
• Create BOM based on copying from another BOM
• Create BOM by manually adding item
• Change BOM to change status
• Change BOM to change component
• Display BOM
• Display BOM multi-level BOM explosion
• Display where-used list

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PP Master Data: Routing

PP Master Data: Routing

• Key Transactions:
• CA01 / 02 / 03: Create/change/display Routing
• CA11 / 12 / 13: Create/change/display Reference Operation Set
• CA80: Work center where-used list

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PP Master Data: Routing

• Questions
• What is the purpose of control key?
• Which master data must be created before routing?

PP Master Data: Routing

• Exercises
• NOTE:
• Operation 0700 is used for Last production operation, set Control key as “ZP02”
• Operation 0800 is used for QC, set Control key as “ZP04”
• Operation 0900 is used for Rework, set Control key as “ZP05”
• Operation 9000 is used for ECR, set Field key as “Z000001”, set Control key as “ZP06”
• Create Routing based on copying from another BOM
• Create Routing by manually adding operation
• Change Routing to change status
• Change Routing to change operation

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Agenda

1. Training Approach
2. Training Data
3. PP Master Data
4. Planning and MRP
5. Shop Floor Control
6. Engineering Change Request

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Planning and MRP: Overview

Run MRP & Evaluate

the result

Transfer SOP to Demand Management

Manual process to get firm sales plan for next quarter for Finished good/Planning Material

Maintain sales plan into in SOP version

Maintain SOP

MC87 / MC88

Export Demand Management

MD79

Reorg Demand Management

MD74 / MD75 / MD76

Transfer SOP to Demand Management by Mass Processing

MC8D , MC8G, MC8I

Run MRP online

MD01

Run MRP scheduled

MDBT

Planning and MRP: Overview

• MRP procedure
• Calculates net requirements
• Determine lot-sizing procedure
• Determine Procurement type
• BOM explosion and dependent requirements
• Reference: http://help.sap.com/saphelp_erp60_sp/helpdata/en/f4/7d3f9344af11d182b40000e829fbfe/frameset.htm

Planning and MRP: Overview

• Sales plan can be created for planning materials and finished goods.
• SOP versions are use to record different sales plan. E.g. each version represents a sales plan as of each month.
• If necessary, production/stock plan can also be manually created for semi-finished or raw materials.

Planning and MRP: SOP

• Key Transactions:
• MC87 / 88 / 89: Create/change/display Plan
• MC74: Single material transfer from SOP to Demand management
• MC8D / E / F / G: Create/change/delete/schedule Planning job
• ZPPQ0001: List of Planning Materials-Finished Goods
• ZPPxxxxx: Upload SOP program
• SE16N: See table S076

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Planning and MRP: Demand Management

• Key Transactions:
• MD61 / 62 / 63: Create/change/display Planned independent requirements (PIR)
• MD74: Adjust Requirements
• MD75: Reorg Schedule Lines
• MD76: Delete History
• MD79: Export Requirements to Excel

Planning and MRP: MRP

• Key Transactions:
• MD01: Online total MRP Run
• MDBT: Background total MRP Run
• MD02: Single-item, Multi-level MRP Run
• MD07 / 04: Collective/Individual Stock/Requirement List
• MD06 / 05: Collective/Individual MRP List
• MD44: Planning Situation

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Planning and MRP

• Questions
• Does SOP data affect MRP?
• Is MRP planning forward or backward looking?
• What is the difference between MRP list and Stock/requirement list?
• What is the purpose of Re-org planning data?
• What does MRP controller represent?
• When is the Sales plan deducted?

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Planning and MRP: SOP

• Exercises
• Create Sales plan in SOP for 3 materials
• 1 Planning material
• 2 Finished Goods
• Transfer SOP to Demand Management for single material
• Transfer SOP to Demand Management by Mass processing

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Planning and MRP: Demand Management

• Exercises
• Change Demand Management
• Export Demand Management as Excel

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Planning and MRP: MRP

• Exercises
• Run Online MRP for single-material, multi-level
• Run Online MRP for whole plant
• Run Scheduled MRP for whole plant
• Display MRP Results
• Collective view
• Individual material view, also see dependent requirements drill-down
• Planning situation view
• Re-org planning data at the start of new period

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Agenda

1. Training Approach
2. Training Data
3. PP Master Data
4. Planning and MRP
5. Shop Floor Control
6. Engineering Change Request

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Shop Floor Control: Overview

Shop Floor Control: Overview

Order proposal

Order creation

Availability check

Order release

Material withdrawal

Order print

Execution

Confirmations

Warehouse receipt

Order settlement

Shop Floor Control

• Key Transactions:
• CO01: Create Production order for Make-to-stock
• CO08: Create Production order for Make-to-order
• CO40 / 41: Create Production order by conversion from Planned order
• CO02 / 03: Change / Display Production order
• COHV: Mass processing of Production Orders
• ZCO02R: Release Production order with Missing part
• ZCO02E: Change Production order by Engineering Change Manager
• CO11N: Enter Confirmation
• CO13: Cancel Confirmation
• COOIS: Production Order Information System
• MIGO (movement type 261): Goods issue to Production order
• MIGO (movement type 101): Goods receipt from Production order

Shop Floor Control

• Questions
• What is the difference between a MTS and MTO Production order?
• What is the difference between forward and backward scheduling?
• At what status is a Production order considered “completed”?

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Shop Floor Control: Production Order Processing

• Exercises
• Convert single Planned order (from MRP proposal) to Production order
• Manually create a MTO Production order
• Collectively convert Planned orders to Production orders
• Release Production order without missing part
• Release Production order with missing part
• Print Production order
• Change Production order
• Header
• Operations
• Components
• Display Production Order Information System
• Mass Processing for Production Orders
• Release
• Print
• TECO

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Shop Floor Control: Production Order Goods Issue

• Exercises
• List of required and issued components
• Goods issue to Production order based on reservation
• Goods issue to Production order without reservation
• Return from Production order to store (reverse goods issue)

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Shop Floor Control: Production Order Confirmation

• Exercises
• Confirmation of operations (note backflush)
• Cancel Confirmation

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Shop Floor Control: Production Order Goods Receipt

• Exercises
• List of Production orders that completed production but not yet QA (Layout = /Z0001; Order header status selection profile = ZQA0001)
• Goods receipt from Production order (enter batch info)

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Agenda

1. Training Approach
2. Training Data
3. PP Master Data
4. Planning and MRP
5. Shop Floor Control
6. Engineering Change Request

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Engineering Change Request

• Key Transactions:
• CO02: Change Production order, Operation 9000
• ZCO02E: Change Production order, Operation 9000, change Components
• COOIS: Production information system, Operation list,

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Engineering Change Request

• Questions
1. Where is ECR recorded?

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Engineering Change Request

• Exercises
• Requestor: Initiation Create ECR Production order (ZCO01E)
• Change the component
• ECR number
• Quantity
• Set status : request ECR (header)
• Hardcopy approve trial
• Requestor : Release and execute ECR Production order (CO02)
• ECR: Check result and set status (Approve/Reject) (ZCO02E)
• ECR: Change component in original order (ZCO02E)

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• List of Production orders (COOIS)
• ZECR001 All WO with ECR
• ZECR002 List of WO - Request ECR Trial
• ZECR003 List of WO - ECR Trial Approve
• ZECR004 List of WO - Approved ECR
• ZECR005 List of WO - Rejected ECR

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Q & A raised during training

• Uom sht only whole number?
• Turn off alt bom?
• Change default bom base qty to 1000
• Stock transfer from 1 cust stock to another (planner)
• Assembly scrap in mat master
• Create so, email to ms gan
• Create new QA FG production storage location
• Md74 sap bug, search help for material
• Mc74 Factory calendar up to 2010
• Routing has long text
• Remove user field, ECR quantity, request date, completed date
• Remove user status Approved for Trial

Thank you!