Production Planning and Control

Overview Training
 DAY-1 OBJECTIVES
• What is an ERP?
• SAP Implementation at MIDAS
• What is Master Data?
• Production Planning Material Master views
• Bill of Materials
 MASTER DATA
PRODUCTION PLANNING &
CONTROL
OVERVIEW TRAINING
DAY - 1
 SAP @ MIDAS
• Our scope involves:
– Sales & Distribution (SD)
– Materials Management (MM)
– Production Planning (PP)
– Plant Maintenance (PM)
– Quality management (QM)
– New Product Development (NPD)
– Financial Accounting (FI)
– Controlling (CO)
– Human Capital Management (HCM)
– Customer Relationship Management (CRM)
 SAP PROJECT PHASES
Project Preparation Initial
Phase Introductory
Training

Go-Live & Support

Phase Business Blueprint
Phase
MIDAS
To-Be
SAP
Workshops
Project

Final Preparation Realization Phase

Phase
Exercises & End Detailed
User Trainings Training of
Power Users

5
THE VALUE IS THE END-TO-END
SOLUTION
 Quality Control 

Vendors Inbound Transportation

Logistics Manufacturing
Plant Maintenance

 Quality Control 

Warehousing Delivery Distributors Consumers

A TYPICAL ORGANISATION BEFORE
SAP
Customer

use Sa Customer
ho l es
e
Vendor ar
W
Production
Pu
rc
ha ce Customer
si n a n
g Fi n
Vendor
Vendor

 Business functions are separate

 Interface and communication links with other functions
 Variety of information systems
 Each function maintains its own master data
 Duplication of data entry
INTEGRATION OF BUSINESS PROCESSES
AFTER SAP
SAP ORGANISATIONAL UNITS

Company

Plant Plant

Storage Storage Storage Storage

Location Location Location Location
HOW SAP TRANSACTIONS WORK

Data tables
xxxx xxxx xxxx
are files that
xxxx xxxx xxxx
contain
xxxx xxxx xxxx
codes and
xxxx xxxx xxxx
other
xxxx xxxx xxxx
information.

Master Data Records SAP Data Tables

Accessed Accessed

SAP Transaction
Performed

Document Examples of
Documents:
• Customer orders
• Goods issue
• Maintenance
orders
• Vendor invoices

SAP Document Created Data Created for

whenever stock is moved
or money is received
Reporting and Analyzing
 PRODUCTION PLANNING
OVERVIEW

Sales & Operations

Planning

Rough Cut
Material
Master Production
Capacity Scheduling Master
Planning
Work
Centers BOM
Capacity Material
Requirement Requirement
Planning Planning

Inventory
Status
Routing Material &
Capacity Plans
Production
Procurement System Execution
MASTER DATA
MATERIAL MASTER

What is Material Master?

 MATERIAL MASTER
• Types of Materials in SAP
– FERT (finished products)
– FHMI (production resources/tools)
– HALB (semi finished products)
– HAWA (trading goods)
– NLAG (non-stock material)
– ROH (raw materials)
– UNBW (non-valuated materials)
– VERP (packaging materials)
• Material Master Views in SAP
MATERIAL MASTER
MATERIAL MASTER
MATERIAL MASTER
MATERIAL MASTER
MATERIAL MASTER
MATERIAL MASTER
MATERIAL MASTER
MATERIAL MASTER
BILL OF MATERIALS
(BOM)
 BILL OF MATERIAL (BOM)
• Bill of Material (BOM)
– Comprehensive, formally structured list of
components that make up a product

Single Level BOM

 BILL OF MATERIAL (BOM)

• Low level
code : 000

• Low level
code : 001

• Low level
code : 002

Multi Level BOM

 BILL OF MATERIAL (BOM)
• BOM Categories
 BILL OF MATERIAL (BOM)
• BOM Usage
 BILL OF MATERIAL (BOM)
• BOM Usage
 BILL OF MATERIAL (BOM)
• Effectivity Period
 BILL OF MATERIAL (BOM)
• BOM Structure
– Header
• Status
• Text
• Base Quantity
• Lot size…
– Item
• Status
• Scrap
• Text
• Quantities
 BILL OF MATERIAL (BOM)

Question: How much of Component A and Component B

will be required to produce 150 KG?
Answer:
Component A : 10 x 150 / 100 = 15
Component B : 5 x 150 / 100 = 7.5
• Can you create a Bill of Material for your relevant
Production area?
• Does your Bill of Material have alternatives? Can you
identify one product with more than one BOM?
• What will be the BOM usage for materials in our
area?
• What would be the Low Level Code for a material
that is not attached to any BOM?
 • BOM Upload File

Material Plnt BOM Usg AltBOM Valid From Alt. Text Base quantity BOM St Item ICt Component Quantity Fix Co-pd Allowed C.scrap Costing IsLoc
2000000301 1022 1 1 01.01.2010 Olper's Milk 250ml X 27 1,000.000 01 0010 L 4000000360 4,000.000       0.00 X 0210
            1,000.000   0020 L 4000000303 0.370       0.00 X 0210
            1,000.000   0030 L 4000000346 30.000       0.00 X 0210
            1,000.000   0040 L 4000000344 120.000       0.00 X 0210
            1,000.000   0050 L 4000000388 1.800       0.00 X 0210
            1,000.000   0060 L 4000000329 0.089       0.00 X 0210
            1,000.000   0070 L 1000000500 1,000.000       0.00 X  
2000000303 1022 1 1 01.01.2010 Olper's Milk 500ml 1,000.000 01 0010 L 4000000362 2,000.000       0.00 X 0210
            1,000.000   0020 L 4000000303 0.227       0.00 X 0210
            1,000.000   0030 L 4000000348 166.670       0.00 X 0210
            1,000.000   0040 L 4000000318 126.000       0.00 X 0210
            1,000.000   0050 L 1000000500 1,000.000       0.00 X  
QUESTIONS?
PRODUCTION PLANNING AND
CONTROL
OVERVIEW TRAINING
DAY - 2
 DAY-2 OBJECTIVES
• What are Work Centers?
• Creating Work Centers in SAP
• Defining Work Center Capacities
• Shifts and Shift Sequence?
• What is Routing?
• Creating Routing data in SAP
• What are Production Versions?
• Creating Production Versions in SAP
WORK CENTERS
 WORK CENTERS
• A location where a particular operation is executed.
• a location where the capacity of production
resources is consumed.
WORK CENTERS
WORK CENTERS
WORK CENTERS
 WORK CENTERS
• Machine
Formula’s can be created using:
•• Setup
Person
•• Machine
Processing unit
•• Labor
Warehouse
•• Base
Warehouse + proc. unit
quantity
• Operation quantity
• Production time
• Teardown
• Pkg Labor, etc.
WORK CENTERS
Shift Definition

Shift Sequence
WORK CENTERS
 WORK CENTERS
• Scheduling
– Scheduling basis
• capacity whose operating time is to be used for
scheduling orders.
 WORK CENTERS
• Interoperation Time
WORK CENTERS
 WORK CENTERS
• Work Center Hierarchies
– Work centers can be grouped into a work center hierarchy
– One work center can exist in multiple hierarchies
– Can include several Plants
– Used in capacity planning to cumulate available capacity
and capacity requirements
WORK CENTERS
• Work Center Upload File
– Basic Data View
BASIC DATA

WERKS RESOURCE VERWE STEXT VERAN PLANV RGEKZ VGWTS

Person
responsible
for the Indicator:
Resource work Key for task Backflushin Standard
Plant Resource category Object Name center list usage g value key
1021AMIX-001 0008SKZ Plant-Almix/Powder Mixer 001 009X ZEFL
1021PSMIX-01 0008SKZ Plant-Powder/Sugar Mixers 001 009X ZEFL
1021PSMIX-03 0008SKZ Plant-Powder/Sugar Mixers 001 009X ZEFL
1021PAS-001 0008SKZ Plant-Pasteurizer 1 001 009X ZEFL
• Work Center Upload File
– Default Values
DEFAULT VALUES

STEUS VGEXX_01 VGEXX_02 VGEXX_03 VGEXX_04 VGEXX_05 VGEXX_06

Unit of Unit of
Unit of Unit of Unit of measure for Unit of measure for
measure for measure for measure for the TPP measure for Primary
Control key Energy Labor TPP Chemical Maintenance CIP Freight
PI01 HR AU AU AU AU AU
PI01 HR AU AU AU AU AU
PI01 HR AU AU AU AU AU
 • Work Center Upload File
– Capacities View
CAPACITIES RESOURCE CAPACITY

KAPART_0
1 FORKN_01KTEXT PLANR MOSID BEGZT ENDZT PAUSE NGRAD AZNOR KALID MEINS KAPLPL KAPEH

Formula Indicator:
for cap. Long-term
reqmts. Grouping Base Unit planning
for other for shift Cumulativ Capacity Number of takes Unit of
types of Capacity definitions e length utilization of Factory Measure capacity measure
Capacity int. planner and shift Finish of breaks rate individual calendar ment for into of
category processingCapacity short text group sequences Start time time per shift (percent) capacities ID Capacity account capacity

001 ZENRGY Standard Capacity 00101 08:00:00 07:59:59 01:30:00 90 1ZP HR X HR

001 ZENRGY Standard Capacity 00601 08:00:00 07:59:59 01:30:00 90 1ZP HR X HR

001 ZENRGY Standard Capacity 00501 08:00:00 07:59:59 01:30:00 90 1ZP HR X HR

• Work Center Upload File
– Resource Intervals and Scheduling view
RESOURCE INTERVALS/SHIFTS SCHEDULING

KAPTER VERSN SHIFTDEF SEL_FLAG_01 DATUV_01 DATUB_01 SPROG_01

Indicator:
Capacity
relevant to Available Key for the
finite capacity Valid-From shift
scheduling version Shift Def. General Flag Date Valid-to date sequence

X 1 1X 1.1.2010 31.12.9999 1

X 1 1X 1.1.2010 31.12.9999 1

X 1 1X 1.1.2010 31.12.9999 1
• Work Center Upload File
– Costing View
COSTING

KAPART FORTN BEGDA ENDDA KOSTL LARXX_1 LEINH_01 FORXX_01 LARXX_2 LEINH_02 FORXX_02

Formula for
the
duration of
other types Energy Energy Energy Labor Labor Labor
Capacity of int. Activity Activity Formula Activity Activity Formula
category processing Start Date End Date Cost Center Type Unit key Type Unit key

001 ZENRQS 01.01.2010 31.12.9999 1116163 900100HR ZENRGY 900200AU ZDLAB

001 ZENRQS 01.01.2010 31.12.9999 1116164 900100HR ZENRGY 900200AU ZDLAB

001 ZENRQS 01.01.2010 31.12.9999 1116165 900100HR ZENRGY 900200AU ZDLAB

• Can you list down work centers in your production
area?
• How can we calculate capacity at MIDAS?
• Can you identify a few activity types in your work
centers?
• Can Labor be created as a work center in SAP?
• What is the use of a Factory Calendar?
• Can you create a Work Center hierarchy for your
production area?
QUESTIONS?
ROUTING
 ROUTING
• describes the sequence of activities to be performed
– Where the work is performed?
– How long will the work take?
– What materials to use for each operation?
 ROUTING
• is independent of an order.

• planned time for each operation is stored in a routing

• These standard values are the basis for

– Lead time scheduling
– Product costing
– Capacity planning
 ROUTING
• Routing Usage
 ROUTING
• Routing Structure
ROUTING
 ROUTING

• The routings in a group are differentiated using the group counter.

Routings are identified by their group and group counter values.
• Groups contain routings that have similar production processes
• One routing can be used to produce several materials.
• Routing
– Header
 Capacity
Group Group Lot size Base
MaterialPlant Profile Key Date Status Usage Planner Lot size to UoM
Number Counter from Quantity
Group

MAPL MAPL MAPL MAPL PLKO PLPO PLKO PLKO   PLKO PLKO PLPO PLPO

PLNNR PLNAL MATNR WERKS PROFIDNETZ DATUV STATU VERWE   LOSVN LOSBS BMSCH MEINH

50002001 1 2000000346 1022PI01 01.01.2010 4 1 007 1 99999999 90,000.00L

                         

50002002 1 2000000347 1022PI01 01.01.2010 4 1 007 1 99999999 90,000.00L

                         
• Routing
– Operations
 Control
Op/Phas Phase Superior
Recipe Resourc Contro Operation Maintaine
e Indicat Operatio Description UOM Machine Labor Chemical CIP Freight
Destinat e l Key Quantity nce
Number or n
ion

PLPO PLPO   PLPO CRHD PLPO PLPO   PLPO PLPO PLPO PLPO PLPO PLPO PLPO

VORNR PHFLG   PHSEQ ARBPL STEUS LTXA1   MEINHVGW01 VGW02 VGW03 VGW04 VGW05 VGW06
Packing in consumer
0010      TBA08-A PI01 pack 90,000.00L 0 0 0 0 0 0
Packing in consumer
0020X   01TBA08-A ZEFL pack 90,000.00L 15 90,000.00 90,000.00 90,000.00 0 0
Packing in consumer
0010      TBA08-A PI01 pack 90,000.00L 0 0 0 0 0 0
Packing in consumer
0020X   01TBA08-A ZEFL pack 90,000.00L 15 90,000.00 90,000.00 90,000.00 0 0
PRODUCTION VERSIONS
 PRODUCTION VERSION
• A combination of BOM and Routing
PRODUCTION VERSION
 • Production Version
Receivi
ng
Propos storage
ed issuelocation
Lower storage for
value of Upper Valid-from Run-time Task Key for location repetiti
the lot- value of date of end: List Task Alterna for ve
Material Production Short text on the size the lot-size production production Typ List tive BOM compo manufa Group
Plant Number Version production version interval interval version version e Group BOM Usage nents cturing Counter

500020
1022 1000000500 0001Production Version desc 1 9900001.01.2010 31.12.9999 2 69 1 1 1

500020
1022 1000000501 0001Description 2 1 9900001.01.2010 31.12.9999 2 20 1 1 1

500020
1022 1000000501 0002Description 3 1 9900001.01.2010 31.12.9999 2 21 1 1 1
QUESTIONS?