TSCM32 Manufacturing II Part 2
TSCM32
Manufacturing II
Part 2 of 2
THE BEST-RUN BUSINESSES RUN SAP
SAP AG 2004
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
SAP R/3 Enterprise, System Landscape Fx4

2004/Q3
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Material number: 50071566
© SAP AG
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Copyright
Copyright 2004 SAP AG. All rights reserved.
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Solution Consultant mySAP SCM - Manufacturing
TSCM20 10 days
TSCM32 10 days
TSCM34 5 days
Planning/Manuf. I
Manufacturing II
Manufacturing III
(Case Study)
Certification
 SAP AG 2004
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Course Overview
Contents:
 Course Goals
 Course Objectives
 Course Content
 SAP AG 2004
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Course Goal
At the conclusion of this course, you will be able to:
 Use and configure basic functionalities of
manufacturing with production orders
 Use and configure basic functionalities of
repetitive manufacturing
 Consider possibilities of capacity planning
in manufacturing
 SAP AG 2004
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Course Content: TSCM32 Manufacturing
Preface
Unit
Course Overview
Unit
Production Orders
Unit
Repetitive Manufacturing
Unit
Overview Capacity Planning
Unit
Overview SAP Solution Manager
Unit
Preparation of Certification
Unit
Review
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Course Content: Production Orders
Unit 1
Course Overview
Unit 8
Order Control
Unit 2
Introduction
Unit 9
Confirmations
Unit 3
Order Creation /
Order Change
Unit 10
Goods Receipt
Unit 11
Settlement, Archiving
and Deletion
Unit 4
Integration for Planning
Unit 5
Order Release
Unit 12
Information Systems
Unit 6
Printing Order Documents
Unit 13
Mass Processing and
Automation
Unit 7
Material Staging
Unit 14
Collective Orders
Appendix
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Course Content: Repetitive Manufacturing
Unit 1
Introduction
Unit 5
Material Staging
Unit 2
Production Types Overview
Unit 6
Backflushing
Unit 3
Master Data
Unit 7
Evaluations
Unit 4
Planning
Unit 8
Conclusion
Appendix
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Course Content: Overview Capacity Planning
Unit
Overview Capacity Planning
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Course Content: Overview Solution Manager
Unit
Overview Solution Manager
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Course Content: Preparation of Certification
Unit
Preparation of Certification
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Course Content: Review
Unit
Review
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Unit: Repetitive Manufacturing
 SAP AG 2004
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Course Overview
Contents:
 Course Goals
 Course Objectives
 Course Overview Diagram
 Course Content
 Main Business Scenario
 The Concept of Roles
 SAP AG 2004
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Course Goals
This course will prepare you to:
 Position repetitive manufacturing correctly within the
complete mySAP SCM environment (demand
management, material requirements planning, sales
order processing ...)
 Work with or implement repetitive manufacturing with
its essential basic functions
 Understand and use the basic functions of repetitive
manufacturing in detail
 Consider the integration relationships of repetitive
manufacturing
 Use self-study to learn further special functions
 SAP AG 2004
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Course Objectives
At the conclusion of this course, you will be able to:
 Maintain master data for repetitive manufacturing
 Execute line loading for repetitive manufacturing
 Execute material staging for repetitive manufacturing
 Execute backflushing for repetitive manufacturing
 Execute evaluations for repetitive manufacturing
 SAP AG 2004
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Course Content
Preface
Unit 1
Introduction
Unit 5
Material Staging
Unit 2
Production Types Overview
Unit 6
Backflushing
Unit 3
Master Data
Unit 7
Evaluations
Unit 4
Planning
Unit 8
Conclusion
Appendix
 SAP AG 2004
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Main Business Scenario
 You are a manufacturer. In your plant 1200 in Dresden, you
manufacture PCs and PC assemblies on several production lines.
Production is quantity- and period-based. In your company, you
belong to the team that is implementing mySAP SCM Repetitive
Manufacturing. To do this, you have to realize the complete
process chain for in-house production, which would allow you
to organize, control and execute production for a plant on the
basis of the R/3 System and, if required, APO System.
 Important stations of quantity and period-based production are:
dispatching quantities to the production line taking capacity into
account, printing the production list, staging materials,
backflushing manufactured quantities and settling the product
cost collector.
 In practice, these functions are integrated with other areas (such
as controlling and materials management) in your company.
Therefore, during the implementation, you must take extensive
integration relationships of repetitive manufacturing into
account.
 SAP AG 2004
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
Demonstration example: Repetitive manufacturing personal computers (PCs) and PC assemblies are
manufactured in plant 1200. Finished PCs are produced on a make-to-order basis while assemblies
are produced to stock. Two production lines are available for manufacturing the assemblies and for
final assembly. The components for the assemblies are transferred from the material warehouse via
the pull list or are replenished using KANBAN. When backflushing the assembly, the goods receipt
for the assembly is posted directly to the storage location assigned to the final assembly production
lines. On the other hand, components required for final assembly and not produced on the assembly
production lines are transferred from the material warehouse via the pull list.

The description of the most important data in the training system and in the IDES system are as
follows (for detailed BOMS, see appendix):
Material numbers:
T-F10##
(IDES: R-1000)
PC Maxitec R-375 (final assembly in make-to-order production)
T-F13##
(IDES: R-1003)
PC Maxitec R-375 (Final assembly in make-to-stock production)
T-B10##
(IDES: R-1110)
Motherboard for T-F10## (assembly production to stock)
T-B11##
(IDES: R-1112)
Motherboard for T-F13## (assembly production to stock)
T-B20##
(IDES: R-1120)
Cable
T-B30##
(IDES: R-1130)
Keyboard
T-B40##
(IDES: R-1140) TFT monitor
T-B50##
(IDES: R-1150)
Floppy disk drive
T-B60##
(IDES: R-1160)
Hard disk for T-F10##
T-B61##
(IDES: R-1161)
Hard disk for T-F13##
T-B70##
(IDES: R-1170)
PC casing
T-B80##
(IDES: R-1180)
CD-ROM drive
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
Production lines:
T-L1## (IDES: LINE1)
T-L2## (IDES: LINE2)
T-L3## (IDES: LINE3)
T-L4## (IDES: LINE4)
© SAP AG
Production line 1 (for production of PC)
Production line 2 (for production of PC)
Production line 3 (for production of motherboard)
Production line 4 (for production of motherboard)
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
Demonstration Example: KANBAN Personal computers (PCs) and PC assemblies are
manufactured in plant 1200. Two production lines are available for manufacturing the assemblies
and for final assembly. The components for the assemblies are procured externally using KANBAN,
manufactured in-house, or transferred from the material warehouse. On the other hand, components
required for final assembly not produced on the assembly production lines are transferred from the
material warehouse using KANBAN.

The description of the most important data in the training system and in the IDES system are as
follows:
Material numbers:
T-F10## (IDES: R-1000)
PC Maxitec R-375 (Final assembly in make-to-order production)
T-B10## (IDES: R-1110)
Motherboard (Assembly production to stock)
T-T7## (IDES: R-1230)
BIOS (For KANBAN external procurement with purchase order)
T-B7## (IDES: R-1240)
Processor cooling unit (KANBAN in-house production with planned
order)
T-T8## (IDES: R-1310)
Aluminium heat sink (KANBAN stock transfer with reservation)
T-T9## (IDES: R-1330)
Fan 5V (KANBAN stock transfer without reservation)
Production lines:
T-L1## (IDES: LINE1)
Production line 1 (for production of PC)
T-L3## (IDES: LINE3)
Production line 3 (for production of main circuit board)
T-L5## (IDES: LINE5)
Production line 5 (for production of processor cooling unit)
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
The following objects/tasks lie within Stephen's area of responsibility:
Work centers, capacities, hierarchies, routings, classification (objects relevant to production) and
rules for configuration (routings).

He processes the following objects in agreement with engineering/design:
Material master records, configuration (complete), material - plan assignment.
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
The following objects/tasks lie within Tanja's area of responsibility: Dispatching, sequencing, sales
order/planner order management, capacity load, monitoring scheduling, forecast (extra single role),
sales clerk (extra single role).

She requires display authorization for the following master data: Production versions, line design
(work centers, rate routings, line balancing, operational method sheet), material master, material
BOMs, production resources and tolls, serial number maintenance, documents, supply areas, product
cost collectors, preliminary costing for the product cost collector.

She requires a change authorization for the following planning transactions: Planning table,
sequencing, collective availability check, stock/requirements list, pegged requirements, stock
overview, production list.

She requires authorization for the following evaluations(production): Reporting point overview,
backflushing document overview, total requirements, reporting point statistics, goods receipts
statistics, component consumption, KANBAN info system, KANBAN error display, KANBAN
plant overview, control cycles/kanbans.

She requires authorization for the following evaluations (inventory management): Material
documents, posting and reversal documents and archived documents for the material, stock
overview, wareshouse stock, provision stocks, availability overview, plant overview and purchase
orders.

She requires authorization for the following evaluations (Controlling): Variance analysis, work in
process, planned costs, actual costs, target/actual comparison (variance categories), production
version: line items actual/variance.
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
John is responsible for planned orders in his area, material staging, KANBAN, backflushing,
operational method sheet, plant management (extra single role), cost center management (extra
single role), personnel management (extra single role) and quality management (extra single role).

He requires authorization for the following master data (display and change, if necessary):
Production versions, line design (work centers, rate routings, line hierarchy, line balancing,
operational method sheet), material master, material BOMs, production resources and tools, serial
number maintenance, documents (drawings and so on), control cycles (kanban and WM), supply
areas, delivery schedule, vendor, customer.

He requires authorization for the following planning transactions: Planning table, sequencing,
collective availability check, stock/requirements list, pegged requirements, stock overview,
production list.

He requires authorization for the following material staging transactions: Triggering material
staging, displaying material staging, stock transfer of components, picking, displaying logs.

He requires authorization for the following backflushing transactions: Collective backflush, final
backflush, reporting point backflush, KANBAN backflush, posting with correction
(activities/components), scrap backflush, separate backflush, reversal, postprocessing.

He also requires authorization for evaluations (production, inventory management and
controlling).
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
Ilja is responsible for creating backflushes (reporting point backflush, final backflush), kanban signal
(bar code, manual), reversing backflushes (exception) and goods movements.

He requires display authorization for the following master data: Documents, operational method
sheets, production resources and tools.

He requires display authorization for the following planning transactions: Displaying production
list (order sequence).

He requires display authorization for the following material staging transactions: Material staging
(displaying situation).
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Production Types Overview
Contents:
 Discrete Manufacturing
 Repetitive Manufacturing
 Takt-Based Flow Manufacturing
 KANBAN
 SAP AG 2004
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Overview of Production Types: Course Objectives
At the conclusion of this unit, you will be able to:
 Describe the key differences between the three
production methods discrete manufacturing,
repetitive manufacturing, and KANBAN
 Explain the main difference between standard
repetitive manufacturing and takt-based flow
manufacturing
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Overview of Production Types: Business Scenario
 As a production company, you want to obtain an
overview of the various approaches to production.
 You will hear about discrete manufacturing, repetitive
manufacturing, takt-based flow manufacturing, and
KANBAN.
 SAP AG 2004
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Production Types and Application Areas
Process Manufacturing
Discrete Manufacturing
Special
Special Mechanical
MechanicalEngineering
Engineering
PRODUCT COMPLEXITY
Repetitive Manufacturing
PRODUCT COMPLEXITY
PRODUCT COMPLEXITY
PRODUCT COMPLEXITY
Engineer-To-Order Production
Custom
Custom Mechanical
Mechanical
Engineering
Engineering
Production
ProductionBy
ByLots
Lots
Takt-Based
Takt-BasedFlow
FlowManftng
Manftng
Assembly
AssemblyProduction/
Production/
Assembly-To-Order
Assembly-To-Order
Period-Oriented
Period-Oriented
Manufacturing
Manufacturing
Mass
Mass Production
Production
PRODUCT STABILITY
 SAP AG 2004

Depending on the application, you can implement various production types supported by mySAP
SCM.

Repetitive manufacturing is primarily used where there is high product stability and high
repetitive manufacturing rate as well as low product complexity. Typical industries are, for
example, mechanical engineering, consumer goods, and the electronics industry.
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
Discrete manufacturing (that is, manufacturing with production orders) typically involves
frequently changing products and therefore manufacturing in restricted production lots. Another
characteristic of discrete manufacturing is the varying sequence of work centers through which
different products flow during production.

In repetitive manufacturing, the same product is usually produced over a longer period of time on
one production line. The product is not produced in lots. Instead, a total quantity is produced in a
certain period at a certain rate. Products pass through production in a relatively steady flow. Semifinished products are usually processed further immediately without being put in interim storage.

With KANBAN, production is not planned by a planning department or planner on an on-going
basis. Instead, production of a material is initiated when it is needed by the next higher
manufacturing level.
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Discrete Manufacturing (Order-Based Production)
Lot
Lot
Lot
 Order-based production using
production order
 Production in order lot sizes
(see lot-sizing procedure)
Order Header
Quantities
Dates
Operations
Material components
 Status maintenance (created,
released...) per order
 Availability check for material, capacity,
PRTs per order
 Material provision controlled per order
using material reservations
 Order backflush, operation backflush
Prod. resources/tools
Costs
 Cost monitoring per order or per product
 Plan
 Plnnd
 Actual
 SAP AG 2004

In discrete manufacturing, a production order defines which material is to be produced, where it
is to be produced, using which activities, and on which date. The production order also defines the
resources to be used and the way in which order costs are to be settled.

As soon as a planned order or internal requirement is created by higher-level planning (MRP),
production control transfers the information and adds all the necessary order-relevant data, thus
enabling an order-based procedure.

When a production order is created, the following actions take place:
­ A routing is selected and its operations and sequences copied to the order.
­ The BOM items are copied to the order.
­ Reservations are created for BOM items kept in stock.
­ Planned costs are determined for the order.
­ Capacity requirements are created for the work centers.
­ Purchase requisitions are created for non-stock components and externally processed
operations.
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
In repetitive manufacturing, you create and process production plans on the basis of the period and
quantity (rather than individual lots and orders).

Planned orders with the order type PE (run schedule quantities) give production quantities and dates.
These planned orders are not converted into production orders. A printed list of the planned orders
authorizes production.

The aims of using repetitive manufacturing are to:
• create and process production plans based on periods (rather than individual lots and orders)
• reduce the administration costs for production control, and simplify completion confirmation
via backflushing, while at the same time still being able to use the full range of PPC functions
• reduce controlling costs
© SAP AG
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Rep. Manufacturing in APO with PPM vs. iPPE
PPM Usage (Production Process
Model)
iPPE Usage (Integrated Product and
Process Engineering)
 R/3 as OLTP system
 DI system as OLTP system
 APO only for planning
 APO also for backflushing
 No engineering change
management
 No configurable Products
 No reporting points
 Lead time scheduling
 Takt-based scheduling
(flow manufacturing)
 No product cost planning
 No actual activity entry
 No material staging list
 SAP AG 2004

Within the framework of the mySAP SCM solution you can add a separate system to the R/3
system, such as SAP APO (Advanced Planner and Optimizer) from SAP, for various, often
enhanced planning tasks.

A decisive factor for the attributes of a solution including an APO system in repetitive manufacturing
is the Online Transaction Processing System used (OLTP system, a "supplying" system for master
data, for example, where in practice APO is not used.

When using a DI system (Discrete Industries, for example the industry solution mySAP
Automotive), there are completely different prerequisites for the system, which results in inherently
different system characteristics. The application of this type of connection with APO has been
strongly adapted to the automotive industry (takt-based manufacturing, model mix planning, and so
on).

This course SCM320 is limited to connection of the APO system when using the production
process model (PPM), because this solution uses a connection to the SAP R/3 standard system. For
this reason, the APO system, where present, is solely responsible for any planning tasks.

In individual cases, you can access the advantageous features of the iPPE structure by using an iPPE
runtime object (iPPE RTO) instead of the PPM. However, at present, this is only possible after
consultation with SAP.
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 mySAP SCM offers you two general means of integrating planning and production:
 Planning using the functions from the component APO
 Planning using the functions from the component R/3
 Production is prepared, executed, and controlled with the functions from the R/3 component, but always
according to the production type. Examples of these functions are calculation, material staging, backflush,
goods movements, and settlement.
 Other functions (scheduling, availability check, machine appointment) can be executed using either of the two
SAP components.
 The master and movement data (planned orders, purchase requisitions, purchase orders, stocks, and so on)
are exchanged between the two SAP components using the Core Interface (CIF).
 Certain events (such as backflush, goods receipt) cause the data to be transferred from R/3 to APO or vice
versa.
 Sales orders are usually entered in R/3 and then transferred to APO.
 You can create planned orders using Material Requirements Planning in R/3 (MRP) or in APO using
 a)
Supply Network Planning in APO (SNP).
This realizes cross-plant planning over a long-term period across the entire delivery and
procurement chain. Here, the system creates stock transport requisitions (distribution), planned orders (inhouse production), and purchase requisitions (external procurement) for the relevant production plant.
 b) Production Planning and Detailed Scheduling in APO (PP/DS).
This creates planned orders and purchase requisitions in a defined,
short-term period (production horizon) in the production plant.
 A particular feature of repetitive manufacturing is that during production using planned orders with the
order type RSQ (run schedule quantity), the planned orders are not converted. The order type changes when
the production line is assigned in APO or in R/3.
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
Make-to-stock production You can use repetitive/flow manufacturing for pure make-to-stock
production. This means you produce products with no direct reference to sales orders. The planned
independent requirements from Demand Management are used as the basis for planning. Depending
on your production strategy, the planned independent requirements from Demand Management can
be consumed by sales orders.
The same product is produced repeatedly over a substantial period of time. The product is not
produced in lots. Instead, a total quantity is produced in a certain period at a certain rate. Products
pass through production in a relatively steady flow.
Sales orders are delivered from stock.

Make-to-order production (sales order-based production) You can use repetitive/flow
manufacturing for pure make-to-order production. This means you produce products with direct
reference to the sales orders. The products are stored in the individual customer stock. Sales orders
can be processed separately. A planned order is created with direct reference to the sales order.
Production is therefore controlled using sales orders. The quantities produced cannot be swapped
between the individual sales orders. The produced quantities are stored specifically for the individual
sales order (individual customer stock) and not in the anonymous warehouse stock. If you use variant
configuration, you can plan and manufacture configurable materials using make-to-order repetitive
manufacturing.
Sales orders are delivered from individual customer stock.

Prerequisite: You use the strategy group in the R/3 material master record to control whether you
want to use make-to-stock or make-to-order repetitive manufacturing.
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Material Provision and Backflushing in Repetitive
Manufacturing
BIOS
RAM
Processor
Board
Motherboard
Production line
 Continuous flow over the production line
 Period-based material provision
 Period and quantity-based confirmation (backflush)
 SAP AG 2004

In repetitive manufacturing, products are generally produced repeatedly over a substantial period of
time. However, this does not necessarily mean that large quantities are produced.

Products generally pass through production in a steady flow and several products can be
manufactured on one production line.

The necessary components are staged anonymously at the production line.

At the end of the shift or at the end of a day, you can backflush all the quantities produced together
(daily quantities).

In an exercise concerning repetitive manufacturing for example, the assembly "Motherboard" is
produced. To produce this assembly on the production line, we require the components "BIOS",
"Processor", and "RAM".
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Discrete and Repetitive Comparison
Production Type
Characteristic
Discrete Manufacturing
Repetitive Manufacturing
Order-related,
restricted production lots
Steadily changing products
Quantity-/Period-oriented
production plan
Same/Similar products produced
during a long period of time, rep. mfg
Differing sequence of
different work centers
Complex, routing also used as
operational method sheet
Complex order processing,
status maintenance
Interim storage for
semi-finished products;
Order-based
(reservation, picking)
Line-based, continuous flow
over the production line
Simple, often only one operation
production rate: Quantity per period
Simplified process,
Reduced effort for control
No interim storage,
continuous flow;
Period-based, anonymous,
aggregated;
Backflush
Controlling
Per order/operations
Cost monitoring order-based
or product-based
Period- and quantity-based
Cost monitoring product-based
(period-based: cost collector)
Object
Production order
Planned order (run schedule quantity)
Products
Work centers
Routing
Control
Warehousing
Material
staging
(components)
 SAP AG 2004

A typical characteristic of discrete manufacturing is the frequent switching from one manufactured
product to another. The products are typically manufactured in individually defined lots which are
pushed through the shop floor. Costs are calculated on the basis of orders and individual lots.
 In repetitive manufacturing, products remain unchanged over a certain period of time. The product
is not produced in lots. Instead, a total quantity is produced in a certain period at a certain rate.

Another characteristic of discrete manufacturing is the varying sequence of work centers through
which different products flow during production. The order of work centers is determined in
routings, which can often be very complex. There can be waiting times between the individual
stations. Semi-finished products are frequently placed in interim storage prior to further processing.
 Repetitive manufacturing on the other hand, normally involves a relatively constant flow on
production lines. Semi-finished products are usually processed further immediately without being
put in interim storage. Routings tend to be relatively simple.

In discrete manufacturing, materials are staged with specific reference to the individual production
lots. Completion confirmations for the various steps and processes document the work progress and
enable fine-tune controlling.
 In repetitive manufacturing, components are often staged at the production line without reference
to a particular order. Completion confirmations (backflushes) are less detailed, and the recording
of actual data is simplified.
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Takt-Based Flow Manufacturing in R/3
Materials/planned orders
Cycle
Planned takt time (how often material placed on
line)
Takt-based scheduling and Sequencing
Maximum takt
time (line
speed)
Production line
 Takt-based scheduling: Planned orders for all materials are dispatched to
the production line based on a common takt time with start and end dates
under a day - the takt time is determined previously
 Sequencing: Planned orders are scheduled in an appropriate
sequence according to model mix planning
 Planned orders (run schedule quantities) authorize production
 SAP AG 2004

Takt-based flow manufacturing is a separate production type that can normally be used in cases
where the production process is controlled using a cycle.

The majority of applications of takt-based flow manufacturing are in the automotive industry. This
means that R/3 contains only a basic range of functions, and that more extensive functions have been
implemented in the industry solution mySAP Automotive.

In takted flow manufacturing, takt-based scheduling, and sequence planning for the planned orders
usually takes place simultaneously:
• Takt-based scheduling: In takt-based scheduling in sequencing, every material/planned order
is dispatched to the production line using the same takt time/production rate.
• Sequencing: The individual planned orders can have quite different runtimes due to different
configurations, for example. Therefore, the planned orders have to be dispatched to the
production line and produced in an optimal order sequence.
Using the optimal determination of the planned order sequence, you can avoid a situation where
several long planned orders are produced in sequence on the production line. Such a sequence
would certainly lead to a capacity overload of the production line.
•
Note: "Takt-Based Flow Manufacturing in R/3" is not covered in the course SCM320.
However, the complete course materials for this topic are contained in this course handbook:
The units Material Staging, Backflush, and Evaluations are identical to those in standard
repetitive manufacturing. The differences concerning the Master Data and Planning are
covered in the appendix.
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
In KANBAN, material flow is organized using containers stored directly in production at the
appropriate work centers. Each container contains the quantity of material required by that work
center personnel for a certain period of time. As soon as a container is emptied at the demand
source, replenishment is initiated. The supply source for the required material can be another
place in production, an external supplier, or a warehouse. The demand source can use material
from other containers until the filled container arrives.

The aim is that the production process is controlled by production itself, and that the employee
has to perform fewer manual postings. This self-management and the fact that replenishment
elements are created close to the time they are actually consumed means that stocks are reduced
(replenishment is only triggered when a material is actually required and not before) and lead times
shortened.

KANBAN in summary: With KANBAN, material is staged where it is used. It remains there, in
small buffers, ready for use. Thus, material staging does not need to be planned. Instead, material
that is consumed is replenished immediately using KANBAN.

If KANBAN is implemented with the support of the R/3 system, transmission of replenishment data
can be automated: scanning the barcode on the KANBAN card suffices to transmit the data needed
for procurement and to post the goods receipt upon receipt of the material.
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KANBAN
Production Type
KANBAN
Principle
"Pull production": Consumption controls replenishment, replenishment at
direct request of the demand source
Process
Material flow via containers: Emptying by demand source triggers replenishment
signal (internal pre-production, external vendor, warehouse) requirement-oriented
material demand, close to actual consumption, consumption-oriented replenishment
Technique
Self-regulating control cycles, supply areas
Control
Aim: Self-regulation of the production process, reduction of
manual posting effort, automatic replenishment, no planning for material
staging, replenishment data already available in control cycle
Process optimization and reduction of the process chain, "Lean Manufacturing":
Simplification of the planning process, more employee responsibility, reduction
of the administrative effort in production
Background
Benefits
Reduction of stock levels, reduction of lead times
Backflush
Controlling
By setting KANBAN to FULL (goods receipt)
For each order for a combination with a production order or product-based
cost collector) for a combination with repetitive manufacturing or a production order
Object
KANBAN (container and card) combined with planned/production order
No production planning. Instead, production release!
 SAP AG 2004
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Overview of Production Types: Summary
 Overview of some production types:
 Discrete manufacturing (order-based)
 Repetitive manufacturing
 Takt-based flow manufacturing
 KANBAN
 Basic characteristics of these production types
 In particular, other elements of repetitive
manufacturing
 SAP AG 2004
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Master Data
Contents:
 Logistics Master Data
 Controlling Master Data
 SAP AG 2004
© SAP AG
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Master Data: Course Objectives
At the conclusion of this unit, you will be able to:
 Maintain the master data required for repetitive
manufacturing
 Understand the integration of Controlling
 SAP AG 2004
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© SAP AG
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Master Data: Business Scenario
 In your plant 1200, you use repetitive
manufacturing to produce two PC assemblies.
Four production lines are already available.
 The necessary master data has already been
maintained in the R/3 system, but has to be
checked.
 The plant manager is planning to set up a
second production line for the PC final
assembly. To do this, the work scheduler along
with engineering/design has to create new
master data in the R/3 system.
 SAP AG 2004
© SAP AG
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
The following objects/tasks lie within Stephen's area of responsibility:
Work centers, capacities, hierarchies, routings, classification (objects relevant to production), and
rules for configuration (routings).

He processes the following objects in agreement with engineering/design: Material master records,
configuration (complete), material - plan assignment.
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Overview of Logistics Master Data: Repetitive
Manufacturing
Material Master
BOM
Production Line
Routing
Routing
 SAP AG 2004

For repetitive manufacturing, you must maintain the following logistics master data: material master,
bill of materials, production line and routing. If you do not need to use capacity planning and you
wish to take advantage of simplified cost accounting features (for example, not posting production
activities for materials with a high material cost share), then you do not necessarily need to maintain
a routing for Repetitive Manufacturing.

When you use the APO system for planning, the R/3 system is the only master data system. Settings
that only affect the APO system are referenced at the appropriate points in the planning unit.

As of SAP R/3 4.6, it is no longer possible to create a run schedule header in the master data of
Repetitive Manufacturing.

For planning in the APO system, there is a master data transfer from the R/3 system to the APO
system via the CIF interface. Material master data is mapped in the APO product master, bills of
material and routings are selected using the production version and are transferred to the APO
production process model. Production lines are mapped onto APO resources. For more details, see
the Integration course SCM210.
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Overview Master Data: Material
 Repetitive manufacturing indicator and profile
 Production version(s)
Material master
BOM
Production line
Routing
Routing
 SAP AG 2004

In the material master (MRP view), the Repetitive Manufacturing indicator authorizes the material
for Repetitive Manufacturing. This means you can use all the various production versions of this
material for Repetitive Manufacturing (that is, you can set the indicator Repetitive Mfg Allowed for
version in the production version).

In the Costing and Financial Accounting views, you define the price of the material and the price
control to be used (standard price, moving average price) when valuating the material in
backflushing.
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Material Master: Repetitive Manufacturing Profile
→ Contains numerous
control parameters:
Goods issue
Rpt point 1
 Linking goods issue
of components to
the goods receipt of
the end product
 Reporting point procedure
Goods issue
Rpt point 1
 Production activities during
backflushing
 ...
Goods receipt
Warehouse
 SAP AG 2004
You define the repetitive manufacturing profile in Customizing for Repetitive Manufacturing and
assign it to a material in the material master record. Various standard profiles for typical procedures
are provided with the standard system. The following are examples of what the repetitive
manufacturing profile controls:
 Whether, in backflushing, the system posts goods issues for the components at the same time as
the goods receipt of the assembly or whether you only want it to post the goods receipt
(Backflushing at GR posting indicator). If you set the system to only post goods receipts, the goods
issue for the components must be posted later in a separate transaction.
 Whether, in backflushing, the system posts production activities at the same time as the goods
receipt of the assembly, or whether you only want it to post a goods receipt (Post activities
indicator). If you set the system to post goods receipts only, the production activities must be
posted later in a separate transaction (if, in fact, you want to post production activities).
 When the backflushing processes are separated at final backflush, whether the system should post
the goods issues for the components and/or production activities in a separate transaction or
automatically as a background job at a later point in time (Process control field).
 Which movement types are to be used for the goods movements.
 Whether reporting points will be used (Reporting point backflush fields). Reporting points are
similar to the milestone logic of discrete manufacturing.

You can use the repetitive manufacturing assistant to help you create the repetitive manufacturing
profile. The repetitive manufacturing assistant leads you step-by-step through the list of questions.
Using the preset answers, you can tailor the repetitive manufacturing profile to suit your production
environment.
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
Use: One material can have several BOMs for production. Its production can also be described in
various routings and the material can be produced on various production lines (work centers). The
data for each of the material's production methods is summarized in a production version, which is
assigned to the material.

The production version defines:
 Alternative BOM and BOM usage for the BOM explosion,
 The task list type, task list group, and group counter for the routing. For Repetitive Manufacturing
you enter the routing to be used in the rate-based planning row or the detailed planning row.
 The production line to be used to produce the material.
 Receiving storage location into which the material is placed when backflush backflushing.
 Proposed issue storage location for the components, from which the components are removed
when the assembly is backflushed.
 Indicator: Repetitive mfg allowed for version: Using this indicator in the production version, you
define that the production version can be used in Repetitive Manufacturing. You can post a
backflush for this production version or create repetitive manufacturing inspection lots for the
production version only if this indicator is set. Before you can delete this flag, the system checks
to see whether inspection lots are still available whether planned orders still exist for the
production version or whether the production version has not yet been settled).
© SAP AG
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Mass Maintenance for Production Versions
Selection via plant and material, for example
Plant
Material Production Lock
version
Valid
from/
to
BOM
alternative,
BOM usage
1200
T-B1000
0001
01.01.2000
to
12.31.2005
1
1
T-L300
Line routing
10040
1
1200
T-B1000
0002
01.01.2000
to
12.31.2005
1
1
T-L400
Line routing
10040
2
Production Task list type,
line
Routing group,
Group counter
1200
 SAP AG 2004

Using the mass maintenance of production versions, you can select your production versions
according to material, plant, MRP controller, key date, production line, task list type, task list group,
and group counter. You can also create new production versions from the mass maintenance
transaction.

If you use Repetitive Manufacturing, you must create at least one production version for a material.

If a material can be manufactured in different production versions (for example on different
production lines), you can use quota arrangements or the alternative BOM indicator in planning,
or a manual assignment in the R/3 planning table or in the APO product planning table to
decide which production version is to be used to produce the production quantity.
© SAP AG
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Overview Master Data: BOM
 Repetitive manufacturing indicator and profile
 Production version(s)
Material master
 Planned material consumption
 Storage location for backflush
BOM
Production line
Routing
Routing
 SAP AG 2004

The BOM defines the planned material consumption for the components.

In the status/long text of the BOM item (field: Issue storage location) you can define the issue
storage location from which components are to be backflushed.
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Overview Master Data: Production Line
 Repetitive manufacturing indicator and profile
 Production version(s)
Material master
 Planned material consumption
 Storage location for backflush
BOM
 Production line as simple work center
or in exceptional cases as a line hierarchy
Production line
 Available capacity, cost center assignment
Routing
Routing
 SAP AG 2004

You can represent production lines in the R/3 System as follows:
 Production lines are usually created as simple work centers in R/3. In the work center, you
define from when and to when the production line is available. You enter the production line
created as the work center in the production version in Production line field. This same work
center is specified in an operation of the routing. Note that in simple repetitive manufacturing, the
routing usually has only one operation.
 Production lines which have more than one work center can be represented in a line hierarchy. A
line hierarchy consists of individual line segments (work centers).
You enter the production line created as the line hierarchy in the production version in the
Production line field. The work centers of the line hierarchy are specified in the routing.
© SAP AG
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
For the creation of a production line as a simple work center, you can use work center category 0007
(line work center) or 0011 (line) to separate the repetitive manufacturing work centers from other
work centers at an organizational level. Other work center categories can also be used in Repetitive
Manufacturing.

The work center defines the available capacity (standard or shift sequence). Various capacity
categories can be stored. The formulas used by the system to calculate capacity requirements are
defined in the work center.

You assign the work center to a cost center in order to valuate internal activities. You do this in the
work center itself.

SAP recommends that the most appropriate standard value key to be assigned to a repetitive work
center is SAP3 (Production line planning). For this standard value key, you can set the production
time to Must be entered and the setup and teardown times to Should not be entered (for the times in
the routing).
© SAP AG
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Exception: Production Line as a Line Hierarchy
Shop Floor Production
Line hierarchy
Line4
Line segments
Line4-2
Line4-1
Line4-11
Line4-12
Line4-21
Line4-22
 SAP AG 2004

Use: Production lines are usually created as simple work centers in repetitive manufacturing. The
representation of production lines using line hierarchies makes sense only in the following two
instances:
 If, when dispatching planned orders, you want to use lead time scheduling via the routing and
carry out capacity planning on several line segments. This includes situations such as if your
production is more order-related (for example, if you use production orders) but you want to carry
out capacity planning using the planning table in repetitive manufacturing.
 If, when dispatching planned orders to the production lines, you want to use takt-based scheduling
in sequencing (instead of lead time scheduling via the routing). Compare the topic "Takt-Based
Flow Manufacturing" in the appendix of these course materials.
 You can split a line hierarchy into as many line segments as necessary (work centers) - splitting is
possible over 99 levels. The line segments on the lowest level of the hierarchy are those where work
actually occurs, whereas the work centers on the upper levels are used only for grouping purposes.
 Prerequisites:
 The individual line segments are created as work centers in the R/3 System. You can organize the
work centers using various work center categories (for example, zone, station, and so on). It makes
sense to do this, for example, on the various levels of the line hierarchy.
 The individual work centers are grouped to a line hierarchy via a graphic in the Line Design
menu. The production line displayed by the line hierarchy takes its name from the uppermost work
center.
 Line hierarchies in Repetitive Manufacturing are not the same as work center hierarchies in
discrete manufacturing. Work center hierarchies group different work centers in discrete
manufacturing to execute capacity planning for a work center group. In repetitive manufacturing,
you can use group hierarchies in order to group together different production lines, so that you can
call up more than one production line at a time in the planning table (this is also possible in the
planning table using other selections).
© SAP AG
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Overview Master Data: Routing
 Repetitive manufacturing indicator and profile
 Production version(s)
Material master
 Planned material consumption
 Storage location for backflush
BOM
 Production line as simple work center
or in exceptional cases as a line hierarchy
Production line
 Available capacity, cost center assignment
Routing
Routing
 Standard routing or rate routing
 Operation or operations
 Determine the production rate
(quantity for time) for lead time scheduling
 SAP AG 2004

Use: In repetitive manufacturing, the routing 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 basis for lead time scheduling.
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 one operation. The
total production rate of the line is specified in this operation. This is in order to define 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 in the R/3 System: standard routings and rate routings. 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.
© SAP AG
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Routing
Routing Material A
Task list group 1
Oper- Work
ation center
10
Line3
Control
key
Routing Material A
Task list group 2
Standard
values
Scheduling 30 pc / h
Routing for production of material
A on production line Line 3
Oper- Work
ation center
10
Line4
Control
key
Standard
values
Scheduling 30 pc / h
Routing for production of material
A on production line Line 4
 SAP AG 2004

Routings in Repetitive Manufacturing: As you can achieve a positive performance level when
scheduling routings with only one operation, the following procedure is recommended: Maintain a
routing with only one operation for scheduling where you specify the production rate on the
production line. You define that this operation is valid for scheduling via the control key of the
operation.
Note: The production rate provides no information on the actual lead time of the product over the
production line.
© SAP AG
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
For Repetitive Manufacturing, only the following indicators are relevant in the control key:
Scheduling, Determine CapaReqmts, Cost, Insp. Char. required (for quality management) and
Confirmations (if the Confirmations indicator is set to 3 = Confirmation not possible, then the system
will not backflush activities for this operation).
The other indicators in the control key are not relevant for Repetitive Manufacturing.

If you are working with reporting points (see Backflushing unit ), you use the control key to define
an operation as a reporting point operation. To do this you select a control key, for which the
Confirmations indicator in the control key is set to 1 (=Milestone confirmation).

If you are working with Quality Management, you use the control key to define an operation as one
for which you want to save inspection characteristics. To do this, you select a control key for which
the Inspection characteristic expected is set in the control key.
© SAP AG
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Routing with Several Operations (Example: For
Costing)
Routing Material A
Task list group 2
Routing Material A
Task list group 1
Oper- Work
ation center
Control
key
10
Line3
20
30
40
Line3-1 Costing
Line3-2 Costing
Line3-3 Costing
Standard
values
Scheduling 30 pc / h
2 min / pc
1 min / pc
1 min / pc
Routing for production of material
A on production line Line 3
20
30
40
Oper- Work
ation center
Control
key
10
Line4
20
30
40
Line4-1 Costing
Line4-2 Costing
Line4-3 Costing
Standard
values
Scheduling 30 pc / h
2 min / pc
1 min / pc
1 min / pc
Routing for production of material
A on production line Line 4
The operations specified in the brackets are only maintained in exceptional situations
(for more exact costings, printing the operational method sheets)
 SAP AG 2004

It makes sense to maintain a detailed routing with several operations in the following cases,
 If Controlling requires a detailed version of the routing for costing:
- You maintain further operations for costing or the detailed work description for the employee.
These operations are executed on the individual work centers of the production line. You use the
control key of the operation to define that these operations are not scheduled but only have to be
costed (a line hierarchy is not necessary).
- Alternatively, you can create a routing for scheduling and a routing for the description of the
operations to be carried out by the employee. You then have to enter the routing for scheduling in
the production version because scheduling in the planning table is always carried out using the
routing entered in the production version.
 If you want to describe in detail the steps in the routing to be carried out by the employee: You
define that these operations are not valid for scheduling via the control key of the operation. You
can then print these additional operations using the operational method sheet.
 If, in the planning table, you want to carry out capacity planning for several work centers of a
production line (if production is more order-related). In this case you require several operations
that are relevant for scheduling, which run on the various work centers of the production line. In
this case the production line is created as a line hierarchy.
 If you do not only want to backflush the finished product, but also the intermediate backflushes
(reporting point backflushes) during the production process. In this case you require several
operations that are relevant to scheduling.
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Operational Method Sheet
System R/3
Document
management
Frontend
MS Office
Integration
Routing
Routing
Work
center
A
Assignment:
Material 1
Material 2
PRT 1
Document 1 (as PRT)
Document 2 (as PRT)
B
30
...
20
Document 1
Document 2
Microsoft Word
Operation
Work
center
Production line 1
Operation 20
Work center A
Standard
value
Standard values (times):
...
Material 1
Material 2
PRT 1
Component assignment
• Material 1
• Material 2
Prod. resources/tools:
• PRT 1
Document 1
Document 2
Document 1
Document 2
 SAP AG 2004
 Use: Using this function, you can print out precise work instructions per work center of a production line. An
operational method sheet contains all operations executed on each work center according to the routing. The
operational method sheet can be printed directly at the work center of the production line.
The operational method sheet supports the flexible planning of the personnel capacity (job rotation) as your
employees can learn the new position in another work center quickly using the operational method sheet.
 The system uses Microsoft Word to print the operational method sheets. Here, the data from the R/3 System
(transaction: Print Work Instruction) is transferred to a Word Document from which it is printed.
The following data can be added to the operational method sheet from the R/3 System:
 Tables containing operation data, component assignments or production resources and tools.
 Graphics representing the work process.
 Data on the individual fields from the routing, such as operation text or data from the planning header.
 Prerequisites:
 In R/3, you have created a routing with all the operations and work centers which you want to print via the
operational method sheet. You can use the control key in the routing to maintain a scheduling-relevant
operation for scheduling, as well as maintain operations for printing that are not relevant to scheduling. You
must select these operations in the transaction for printing the work instructions.
 You have created the graphics you want to print out in the document management system of R/3 and
assigned the operations of the routing as production resources and tools.
 In Customizing for the Basic Data, you have defined a layout for the operational method sheet in the Line
Design work step.
 You have set the options of Microsoft Word (Extras Options) so that the integration between R/3 and the
word processing program is smooth (see online help for Line Design).
© SAP AG
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Material Routing Assignment
A
Material
Group
counter
Group
Counter
Routing - Group Counter 1
Material
A
10098
1 (line3)
Oper- Work Standard
ation center values
Line3
10
30 pc / h
Routing - Group Counter 2
Material
B
2 (line4)
Oper- Work Standard
ation center values
Line4
10
25 pc / h
Scenario: On production line "Line3" both material A and material B can be
produced (with the same production rate). On production line "Line4" however,
only material A can be produced.
 SAP AG 2004

The routings of a routing group vary in their group counters, so that a routing can be clearly
identified by specifying the routing group and the group counter.

You can maintain routings in the following (efficient) way, if you can produce several materials with
the same production rate on a production line: Assign the different materials to one routing (material
allocation to routing) instead of maintaining several routings.
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Controlling Integration
Production
Run schedule quantities
Material A
Material B
Planning periods
Time
Controlling
Material A
Product Cost Collector
Material B
Product Cost Collector
Posting periods
Time
 SAP AG 2004

Planning in repetitive manufacturing takes place within the planning periods in the planning table
(for example, period = day).

In the repetitive manufacturing backflush, material costs and production activities are collected at the
product cost collector. Overhead can be posted to the product cost collector using a separate
transaction. The costs that are in the production cost collector may be viewed in a cost report.

The product cost collector is settled periodically according to the posting period (for example,
monthly). The posting periods do not need to match the planning periods in the planning table.

In Discrete Manufacturing, however, costs are tracked per production order. Therefore, each
individual production order is settled.
© SAP AG
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
Use: In Repetitive Manufacturing, all costs attributed to the production of a material are collected on
a product cost collector and settled periodically (period-based Controlling).

If material A, for example, is produced on two production lines, you must create two production
versions. The following options are available to you for collecting costs:

1:1 relationship between product cost collector and production version: costs are collected for each
production version (that is, costs incurred in the production of material A, on two production lines,
are collected separately).

1:N relationship between product cost collector and production version: costs are collected crossproduction version for each material (that is, costs incurred in production of material A, on two
production lines, are collected together).

Prerequisites:
 In the Repetitive Manufacturing menu, you create a product cost collector with order type RM01
(Repetitive Manufacturing product cost collector), you can maintain it manually or make a
collective entry.
 If you want to collect the costs per production version, manually create a different product cost
collector per material, select the key Production version in the screen entitled Controlling Level
for Material and enter the appropriate production version in the Production version field.
Alternatively, you can use the collective entry.
 If you want to collect the costs for all production versions together for one specific material, create
one product cost collector per material, leave the field Production version blank (as this is a multiproduction version product cost collector) and select the Production plant/Planning plant in the
section of the screen entitled Controlling Level for Material.
 With the collective entry, product cost controllers specific to production versions are always
generated.
© SAP AG
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Material Cost Estimate
Motherboard
BOM
Routing
Assembly
Rpt point 10
BIOS
Processor
Burn-in
RAM
Quality check
Rpt point 30
Routing
Cost element
Assembly
Assembly
Assembly
Assembly
BIOS, processor
Direct labor costs
Machine costs
Overhead costs
Mfg costs up to rptg point 10:
Costs
Routing
Cost element
206,00 €
3,00 €
1,77 €
30,90 €
Burn-in
Burn-in
Quality
Quality
Quality
RAM
Burn-in
Direct labor costs
Machine costs
Overhead costs
241,67 €
Mfg costs up to rptg point 30:
Costs
100,00 €
1,22 €
1,60 €
0,88 €
15,00 €
118,70 €
Manufacturing costs of CPU: 360,37 €
 SAP AG 2004

Use: Planned material costs, production activities, and overhead are calculated in material costing.

Components are used in the production of an assembly. Material costs can be calculated for the
components used.

Internal activities are carried out in the production of a material. Production costs can be calculated
for these internal activities. Whether or not production activities are calculated depends on the
control key (Costing indicator) of each operation in the routing. Whether production activities are
costed or not depends on the control key (Costing indicator) for the operation in the routing. The
repetitive manufacturing profile must also allow the posting of production activities. The material
estimate must be created, marked, and released before backflushing can be carried out in Repetitive
Manufacturing.

Overhead costs are costs which can only be indirectly calculated for an order, for example,
electricity or general storage costs.

Repetitive Manufacturing Integration: Production activities can be posted during backflushing in
repetitive manufacturing only if
 the posting of production activities is planned in the repetitive manufacturing profile
 a material cost estimate has been created for the material and the calculated manufacturing costs
have been prebooked and released (in a price update).
When backflushing, production activities are booked on the basis of the routing calculated in the last
material cost estimate (when you post production activities on the basis of the material cost
estimate according to the repetitive manufacturing profile).
© SAP AG
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The Repetitive Manufacturing profile (Cost estimate field) controls:
 Whether activities are backflushed according to the material cost estimate. A material cost
estimate in the form of a standard cost estimate can be released only once a month. With this setting,
backflushing always uses the routing on which the released material cost estimate was based
(Customizing for Controlling, in work step Product Cost Planning: Explosion Control in Costing
Variant). However, since only one released material cost estimate is possible per period, in some
cases this can lead to substantial variances in planned/actual costs. This type of activity backflushing
is appropriate if there is only one production version for a material, or if despite the presence of
various production versions, the routings do not vary much. If you work with several production
versions and each has a different routing, you should calculate a cost estimate per production version
as below. In this way the reference to the correct routing and its associated costs is clear.
 Whether the activities are backflushed according to the cost estimate for the corresponding
production version. Here, you can create an additional cost estimate for each production version on
which the system then bases the activity backflush. Prerequisite: Version-specific product cost
collector). When backflushing, the system therefore takes the routings into account. These are
defined in various production versions.
If this type of activity backflush is set when you create a product cost collector, the system asks if it
should automatically create a cost estimate for the product cost collector (cost estimate for the
production version). The cost estimate however, can also be created later in the product cost collector
by choosing Edit -> Cost. A further function is available which enables you to create cost estimates
for production versions collectively. If the routing has been changed after the preliminary costing of
the product cost collector, the system issues a warning when backflushing. If you confirm this
warning by choosing Enter, a new preliminary costing for the product cost collector is created from
the backflush transaction. (Only when you work with reporting point backflushes and not with final
confirmations.) This ensures that, when backflushing, the production activities are posted on the
basis of the current routing.
© SAP AG
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Master Data: Summary
 Material, BOM, routing, production line as main
logistics master data
 Material costing or additional precosting for product
cost collector (version-specific costing) as a
prerequisite of posting production activities during
backflushing
 Controlling integration: Product cost collector
 SAP AG 2004
© SAP AG
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Exercise Data
Explanation of the symbols in the exercises and solutions
Exercises
Solutions
Course Objectives
Business Scenario
Hints and Tips
Warning or Caution
Not all menu paths are listed in the exercises. This is deliberate so that the course
participants try to learn the menu paths from the instructor’s demos.
Therefore, you can find the menu paths in the solutions to the exercises – especially the
menu paths specific to repetitive manufacturing. Menu paths that are not specific to
repetitive manufacturing (for example, creating a material cost estimate, creating planned
independent requirements or sales orders) are listed in the exercises because it is less important
that you learn them in this course.
© SAP AG
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Data Used in the Exercises
Plant 1200 displays the PC final assembly and the PC assembly production. Different data is
sometimes used in order to demonstrate in particular the different planning functions in SAP
R/3 and SCM (APO) systems.
This data is noted in the following table:
Type of data
Data in training system
Group number
## (00....30)
Company code
1000
1000
Valuation area
1200
1200
Plants
Plant 1200 (Dresden)
Plant 1200 (Dresden)
Purchasing
organization
1000
1000
Sales organization
1000
1000
Distribution channel
10
End customer sale
10
End customer sale
Division
00
Cross-division
00
Cross-division
Customers
1171 (Hightech AG)
1500 (Royal British Rail)
1171 (Hightech AG)
1500 (Royal British Rail)
Industry sector
M
M
Chart of accounts
INT
INT
Controlling area
1000
1000
Cost centers
4275 (Controlling area 1000,
Production PCI)
4276 (Controlling area 1000,
Production PCII)
4277 (Controlling area 1000,
Assembly PCI)
4278 (Controlling area 1000,
Assembly PCII)
4275 (Controlling area 1000,
Production PCI)
4276 (Controlling area 1000,
Production PCII)
4277 (Controlling area 1000,
Assembly PCI)
4278 (Controlling area 1000,
Assembly PCII)
Activity types
1420 Machine time
1420 Machine time
Factory calendar
01
01
MRP controllers
101 PP General
101 PP General
Production lines
(already created as
work centers)
T-L1## (Final assembly)
T-L2## (Final assembly)
T-L3## (Assembly production)
T-L4## (Assembly production)
line1
line2
line3
line4
Work center
hierarchies
L1-5 (only for demonstration)
L1-2
L3-4
© SAP AG
Mechanical engineering
TSCM32
Data in the IDES System
Mechanical engineering
4-27
L1-5
Materials (R/3)
Finished product
Production versions
T-F10## (PC)
0001 (Line T-L1##)
0002 (Line T-L2##)
R-1000
0001 (Line1)
0002 (Line2)
Assembly
Production versions
T-B10## (Motherboard 375)
0001 (Line T-L3##)
0002 (Line T-L4##)
R-1110
0001 (Line3)
0002 (Line4)
Other components
for T-F10##
T-B20## (Cable 220/235 V)
T-B30## (Keyboard, English)
T-B40## (TFT monitor, 17")
T-B50## (Disk drive)
T-B60## (Hard drive)
T-B70## (Slimline PC casing)
T-B80## (CD-ROM drive)
T-B90## (Modem)
R-1120
R-1130
R-1140
R-1150
R-1160
R-1170
Components for
T-B10##
Components for
T-B7##
T-TE## (Processor M-375) for
stock transfer from WM using
material staging list
T-T6## (RAM) for stock
transfer using material staging
list
T-T7## (BIOS) for KANBAN
external procurement
T-B7## (Processor cooling unit)
for KANBAN in-house
production
R-1180C
R-1190C
R-1210
R-1220
R-1230
R-1240
T-T8## (Aluminum cooling
element)
T-T9## (Ventilator 5V)
R-1310
Components for
T-B80##
T-TC## (CD-ROM with label)
R-1250C
Components for
T-B90##
T-TB## (Casing)
T-TD## (Circuit boards)
R-1260C
R-1270C
© SAP AG
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Other assemblies
Production versions
T-B6## (Motherboard 3100)
0001 (Line T-L3##)
R-1111
0001 (Line 3)
Assemblies/Components
T-TA## (Processor M-3100)
T-T6## (Memory)
T-T7## (BIOS)
T-B7## (Processor cooling unit)
R-1211
R-1220
R-1230
R-1240
BOMs
T-F10##
T-B10##
T-B6##
T-B7##
R-1000
R-1110
R-1111
R-1240
Routings
T-F10##
T-B10##
T-B6##
T-B7##
R-1000
R-1110
R-1111
R-1240
WM warehouse
PROD-L3WM
PROD-L3WM
Production supply
area
PVB_L3WM
PVB_L3WM
Finished product
T-F13## (PC)
R-1003
Assembly
T-B11## (Motherboards 375)
T-B20## (Cable 220/235 V)
T-B30## (Keyboard, English)
T-B40## (TFT monitor, 17")
T-B50## (Disk drive)
T-B61## (Hard drive)
T-B70## (Slimline PC casing)
T-B80## (CD-ROM drive)
T-B90## (Modem)
R-1112
R-1120
R-1130
R-1140
R-1150
R-1161
R-1170
Products (SCM/APO)
Components for
T-B11##
Components for
T-B7##
Components for
T-B80##
© SAP AG
T-TA## (Processor M-375) for
stock transfer from WM using
material staging list
T-T6## (RAM) for stock
transfer using material staging
list
T-T7## (BIOS) for KANBAN
external procurement
T-B7## (Processor cooling unit)
for KANBAN in-house
production
R-1180C
R-1190C
R-1212
R-1220
R-1230
R-1240
R-1310
T-T8## (Aluminum cooling
element)
T-T9## (Ventilator 5V)
T-TC## (CD-ROM with label)
TSCM32
R-1330
R-1250C
4-29
Components for
T-B90##
T-TB## (Casing)
T-TD## (Circuit boards)
R-1260C
R-1270C
Production process
model
T-F13##
T-B90##
R-1003
R-1190C
Resources (already
transferred to R/3)
WT-L1##_1200_001 (Final
assembly, Machine)
WT-L1##_1200_002 (Final
assembly, Person)
WT-L2##_1200_001 (Final
assembly, Machine)
WT-L2##_1200_002 (Final
assembly, Person)
WT-L3##_1200_001 (Assembly
production)
WT-L4##_1200_001 (Assembly
production)
Wline1_1200_001
© SAP AG
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Wline1_1200_002
Wline2_1200_001
Wline2_1200_002
Wline3_1200_001
Wline4_1200_001
4-30
Exercises
Unit:
Master Data
Topic:
Logistics Master Data
At the conclusion of this unit, you will be able to
• Maintain the logistics master data required for repetitive
manufacturing
In your plant 1200 in Dresden, final assembly for the Maxitec-R
375 personal computer is carried out on two production lines.
Another two production lines are available for manufacturing the
assemblies of the motherboards.
The plant manager has decided to set up another production line
for the PC final assembly.
You are a work scheduler and your main job is to create and
process master data relevant to production, such as work centers,
routings, and production resources and tools.
As work scheduler, you have to create the necessary master data
for the future final assembly production line in the R/3 System
(work centers, routings).
Moreover, you have to initiate changes to data that does not lie
directly in your area of responsibility (production versions,
master data).
1-1
Create a second production line for the PC final assembly:
1-1-1 The new production line should be created as a work center in plant 1200
(Dresden) with the name T-LZ##.
Use work center category 0007 (line work center) and copy the new
production line using the reference work center T-L1## in plant 1200.
Only copy the following views of the reference production line:
Basic data, Texts, Default values, Capacities, Scheduling, Costing
Change the long text of the production line (work center) to:
Final Assembly – Alternative Production Line
Save your new production line.
© SAP AG
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1-2
Update the existing routing (rate routing) for final assembly so that the PC can also
be produced on the additional production line.
1-2-1 To do this, first go to the rate routing maintenance transaction in create
mode for material T-F10## (Maxitec-R 375 Personal Computer) in plant
1200 and confirm with Enter,
The following screen appears:
Create Rate Routing: Overview.
In the Overview table, you can see the existing routings for material TF10##.
Before you update the routing for final assembly on the additional
production line, check the routing that already exists.
How many group counters currently exist for this material (that is, how
many entries does the table have)?
______________________________________________________
1-2-2 Now have a look at the Operation overview of the first group counter. To do
this, select the row of the first routing and choose the Operations button to
access the operation overview.
On which production line is the material produced, based on this group
counter?
______________________________________________________
1-2-3 What is the production rate, that is, how much of this material is produced
per hour on this production line?
______________________________________________________
1-2-4 Return to the Routing Overview by choosing Goto Header Overview.
After you have checked the existing routing, create a third routing for the
material from the Routing Overview, at first without saving it.
Which group counter number does the system assign to the routing header
when it creates the third routing? Take a note of the new group counter and
the task list group of the rate routing:
______________________________________________________
© SAP AG
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1-2-5 Choose the following text as the description of the new group counter:
Maxitec R 375 assembly line 3.
The new routing should have usage 1 (Production) and status 4 (Released
(general)).
Maintain these parameters as general specifications in the routing header.
To maintain the operations, go from the routing header of the new routing to
the operation overview by choosing the Operations button:
You also want to be able to produce the PC on the third production line TLZ## (which you have already created above). The production rate of the
PC is 30 pieces per hour.
Maintain the rate routing accordingly.
Once you have maintained the operation details of the third group counter,
return from the operation overview to the routing overview by choosing the
following menu path:
Goto  Header Overview
How many routings now exist for your material?
Save.
______________________________________________________
1-3
Create another production version for your PC so that it can also be produced on the
new production line T-LZ## immediately in accordance with the enhanced rate
routing.
1-3-1 To do this, maintain the material master record for your PC (material
number T-F10##) using the change transaction.
Before you create the new production version, first check whether all entries
for repetitive manufacturing have been maintained correctly.
Is the material authorized for repetitive manufacturing?
______________________________________________________
1-3-2 Which repetitive manufacturing profile was selected for the PC?
According to the repetitive manufacturing profile, are production activities
automatically posted to the product cost collector when backflushing this
material?
______________________________________________________
© SAP AG
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1-3-3 Start in the material master with the maintenance of the production version.
Create a new production version 0003 with a text (for example Version
0003 – Alternative Production Line). The production version is to be valid
from today until 12.31.2009.
In the Details for the production version 0003, maintain all the necessary
data so that the PC can also be produced on production line T-LZ##
according to the new rate routing.
The production version is to be valid for a lot-size area of 1 pc to 9.999.999
pieces.
Enter the data for the rate routing (that you save at rate-based planning
level) and the bill of material (Alternative 1, Usage: Production).
The components are to be withdrawn from storage location PL01. The
warehouse receipt is to be posted to the receiving storage location 0002
(finished goods warehouse).
Choose Check in the production version to check the consistency of the
production version. (To check whether the material in the routing and the
BOM are valid with reference to the lot-size range and the validity period of
the production version.)
Confirm the check with Cancel. The routing and the BOM are given a
positive test status in the production version (green traffic light).
After maintaining the production versions, choose Continue to go back to
the material master, via the previous screens, and Save your changes.
© SAP AG
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Exercises
Unit: Master Data
Topic: Controlling Integration
At the conclusion of this unit, you will be able to
• Maintain the Controlling master data required for Repetitive
Manufacturing
• Create a material cost estimate to determine the costs of goods
manufactured for a material
The plant manager has decided to set up another production line
for the PC final assembly.
The work scheduler has maintained the necessary logistics master
data.
Since the costs are to be collected per material and production
version, you have to create a new product cost collector for the
new production version of the PC.
You also have to create a material cost estimate to calculate the
production costs. You then use the production costs calculated as
the valuation price in the material master record of the PC. When
you have late warehouse receipt postings, the stock is then
valuated with this valuation price.
Note: The PC in this example is not a configurable product. The
procedure for valuating configurable materials is covered in the
unit about the backflush.
2-1
Create a version-specific product cost collector for the new production version of
the personal computer (material T-F10##). To do this, use the collective entry.
Menu path:
Logistics  Production  Repetitive Manufacturing  Master Data  Product
Cost Collector  Collective Entry
Field name or data type
Values
Plant
1200
Material
T-F10##
Order type
RM01
The Only Repetitive Mfg. Mat. indicator remains selected.
Execute the report.
With the collective entry of product cost collectors, the
system generally creates version-specific product cost
collectors.
Choose Information Message: What has happened?
© SAP AG
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____________________________________________________________
Note: A (version-specific) product cost collector exists for both production versions
0001 and 0002, which describe the production on lines that are already productive.
Exit the information messages by choosing the Back button several times.
2-2
Here, you use a material cost estimate to calculate the production costs for the
Personal Computer with material number T-F10## (this usually occurs periodically,
for example, once a month). The production costs are to be transferred as the
valuation price in the material master record of the personal computer. The cost of
goods manufactured is the total of component material costs, production activities
and overheads.
2-2-1 Create a material cost estimate for end product T-F10##:
Menu path:
Logistics  Production  Product Cost Planning 
Material Costing  Cost Estimate with Quantity Structure  Create
Field name or data type
Values
Material
T-F10##
Plant
1200
Costing Variant
PPC1
Costing Version
1
Costing Lot Size
1
Confirm once by choosing Enter.
On the Dates tab page, choose:
Field name or data type
Values
Costing Date From
Enter today’s date
Costing Date To
31. December of this year
Confirm with Enter.
What is the cost of goods manufactured for material T-F10##, according
to the material cost estimate?
______________________________________________________
Save the material cost estimate.
Confirm the dialog box that appears next and exit the transaction.
2-2-2 Check the material master to see at what price material T-F10## is currently
valuated:
Menu path:
Logistics  Production  Master Data  Material Master
Material  Display  Display Current
Field name or data type
© SAP AG
Values
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Material
T-F10##
Confirm with Enter.
In the dialog box that appears, select the Costing 2 view
Confirm with Enter and make the following entry:
Plant: 1200
Confirm with Enter.
What is the standard price (Standard Price field)?
______________________________________________________
Leave the material master again to avoid locking the data.
2-2-3 Take a note of the cost estimate for the current period:
Menu path:
Logistics  Production  Product Cost Planning
Material Cost Estimate  Price Update
Field name or data type
Values
Posting period/fiscal year
Enter current month, current
year
Company code
1000
Plant
1200
Material
T-F10##
Delete (deselect) the selection for the Test Run indicator.
Note: Before you can carry out a marking, the instructor
must first allow the marking for company code 1000 and
costing variant PPC1 via the Marking allowance key.
Execute the report.
This updates the cost of goods manufactured for the material, as determined
in the above material cost estimate, as future price in the material master
(Costing 2 view, Planned price field).
Go Back.
2-2-4 Now release the material cost estimate:
Menu path:
Logistics  Production  Product Cost Planning
Material Costing  Price Update
Choose the Release button.
Field name or data type
© SAP AG
Values
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4-37
Posting period/fiscal year
Enter current month, current
year
Company code
1000
Plant
1200
Material
T-F10##
Delete (deselect) the selection for the Test Run indicator.
Execute the report.
This updates the cost of goods manufactured for the material, as determined
in the above material cost estimate, as standard price in the material master
(Costing 2 view, Standard Price field). An inventory revaluation takes
place.
2-2-5 Check in the material master to see at which price material T-F10## is
valuated, now that you have released the material cost estimate. To do this,
access the material master as before, view Costing 2.
What is the standard price (Standard price field) now?
______________________________________________________
2-2-6 Repeat the price update (marking and release) for material T-B10##.
© SAP AG
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Solutions
Unit:
Master Data
Topic: Logistics Master Data
1-1
1-1-1 Menu path:
Logistics  Production  Master Data  Work Centers
Work Center  Create
Field name or data type
Values
Plant
1200
Work center
T-LZ##
Work center category
0007 (line work center)
Reference plant
1200
Reference work center
T-L1##
Confirm with Enter.
The dialog box Copy from... appears. In this dialog box, select the following
options:
Basic data, Texts, Default values, Capacities, Scheduling, Costing.
Choose Copy (Enter).
The screen for work center maintenance appears.
Change the long text of the work center to:
Final Assembly-Alternative Work Center
In work center maintenance, select the Default values tab page in order to copy
the default data.
Now choose the Capacities tab page to check the capacities.
Now choose the Scheduling tab page to check the relevant scheduling data.
Now choose the Costing tab page to check the relevant costing data.
Save.
© SAP AG
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1-2
1-2-1 Menu path:
Return to the SAP Easy Access Menu. From here, choose:
Logistics  Production  Master Data  Routings
Routings  Rate Routings  Create
Field name or data type
Values
Material
T-F10##
Plant
1200
Confirm with Enter.
You can see that a routing already exists for this material with two group
counters. At this time, the material can be manufactured with the aid of two
group counters.
1-2-2 Material T-F10## is produced in the first group counter on production line
T-L1##.
1-2-3 To find out, look at the Base Quantity, Reqmts and Unit columns. The
production rate for material T-F10## on production line T-L1## is 30
pieces per hour.
1-2-4 To create a new routing, choose the New Entries key from the header
overview.
The system assigns the group counter 3 to the new routing.
Take a note of this group counter number and the group (number of the rate
routing).
1-2-5 To maintain the production line in the new routing, enter the production line
T-LZ## in field Work center in the operation overview screen for operation
10.
To maintain a production rate, confirm by choosing Enter in the operation
overview.
To enter a production rate of 30 pieces an hour, enter the following values in
the Default values screen area:
Base quantity:
30 pieces
Production time default value:
1
Unit:
h (hour)
Confirm your entries with Enter.
The control key PP01 was automatically determined as the default value
from the work center.
In the routing overview, you can see that you now have three routings
available for material T-F10##.
© SAP AG
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1-3
1-3-1 Menu path:
Logistics  Production  Master Data  Material Master 
Material  Change  Immediately
Field name or data type
Values
Material
T-F10##
Choose Enter.
In the dialog box that appears, select the MRP 4 view
Confirm with Enter and make the following entry:
Plant: 1200
Confirm with Enter.
The material is allowed for Repetitive Manufacturing as the appropriate
indicator is set in the material master record (Repetitive Mfg).
1-3-2 The repetitive manufacturing profile 0002 has been selected for the PC. You
can find more detailed information on repetitive manufacturing profile 0002
in Customizing for Repetitive Manufacturing. As stated in the long text, in
the case of a backflush for this repetitive manufacturing profile, the
production services are automatically posted to the product cost collector.
1-3-3 To create a new production version, choose ProdVersions from the material
master of T-F10##, MRP 4 view.
In the following dialog box, Production Version Overview, enter the
following data in an empty row:
Field name or data type
Values
Version
0003
Text
Version 0003 – Alternative
Work Center
Valid from:
Enter the current date
Valid to
31.12.2009
To access the detailed maintenance screen for the production version, select
version 0003 and choose the Details key. Maintain the following data:
Lot size from: 1
Lot size to: 9 999 999
In the Planning data section of the screen, maintain the following entries in
the Rate-based planning row:
Task list type: Rate routing
Task list group: Enter the number of your line routing (see above)
Group counter: (See above)
In the BOM section of the screen, maintain the following data:
© SAP AG
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Alternative BOM: 1
BOM usage: 1 (Production)
In the production line field, enter: T-LZ##
You must select the REM Allowed indicator.
In the Other data screen section, enter:
Issue storage location: PL01 (production storage location PL01)
Receiving storage location: 0002 (finished goods warehouse).
After the check, choose Continue to confirm and then Save your changes.
© SAP AG
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Solutions
Unit: Master Data
Topic: Controlling Integration
2-1
Collective entry has created a version-specific product cost collector for the new
production version of the material.
2-2
2-2-1 The cost of goods manufactured in the row is displayed in the Cost of goods
manufactured row.
2-2-3 - No solution necessary 2-2-4 - No solution necessary 2-2-5 You can find the costs of goods manufactured from the standard price field
in the material master record.
2-2-6 Procedure as for 2-2-2 through 2-2-5, but for material T-B10##.
© SAP AG
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Planning
Contents:
 Planning in R/3
 Creating a demand program
 Line loading planning in the R/3 planning table and
sequencing in the capacity planning table
 Planning table functions
 Printing the production list
 Planning using both R/3 and APO:
 Creating a demand program
 Line loading planning with the APO product planning table
 Functions in the APO product planning table
 Printing the production list
 SAP AG 2004
© SAP AG
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Planning: Course Objectives
At the conclusion of this unit, you will be able to:
 Create a production plan for repetitive
manufacturing products using only R/3, or using
both R/3 and APO
 Assign production quantities to production lines,
taking capacity into account
 Use the main functions of the planning tools in
repetitive manufacturing
 Print out the master plan for production list)
 SAP AG 2004
© SAP AG
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© SAP AG
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Planning: Business Scenario
 In your plant 1200, you use repetitive manufacturing
to produce PCs and PC assemblies. Final assembly
and assembly production can both be carried out on
two production lines.
 You have to plan the production quantities in the
system. You can do this using either R/3 alone or both
R/3 and APO.
 The production quantities must then be assigned to
production lines, taking capacity into account, and
the master plan must be printed out for production.
 SAP AG 2004
© SAP AG
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Multiapplication Functional Process
Plnd ind.
reqmnts
Demand program
Sales/distribution
Sales
orders
Costing
Stock
Planned orders
MRP
Planned orders
(RSQ)
Repetitive manufacturing
B
A C D
E
Capacity planning
Material forecast
Production
Backflush with goods receipt
Settlement cost collector
Goods issue
 SAP AG 2004

The complex process chain from the independent requirement to the goods issue of the end product
is displayed in a reduced form in Repetitive Manufacturing.

Examples of typical characteristics are the use of planned orders for manufacturing (there is no
conversion into production orders, the order type of the planned order merely changes to "Run
schedule quantity" (PE) when you assign the production version), and backflush of the end
products with a simultaneous backflush of the components used.
© SAP AG
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
The following objects/tasks lie within Tanja's area of responsibility: Dispatching, sequencing, sales
order/planner order management, capacity load, monitoring scheduling, forecast (extra single role),
sales clerk (extra single role).

She requires display authorization for the following master data: Production versions, line design
(work centers, rate routings, line balancing, operational method sheet), material master, material
BOMs, production resources and tolls, serial number maintenance, documents, supply areas, product
cost collectors, preliminary costing for the product cost collector.

She requires a change authorization for the following planning transactions: Planning table,
sequencing, collective availability check, stock/requirements list, pegged requirements, stock
overview, production list.

She requires authorization for the following evaluations (Production): Reporting point overview,
backflushing document overview, total requirements, reporting point statistics, goods receipts
statistics, component consumption, KANBAN info system, KANBAN error display, KANBAN
plant overview, control cycles/kanbans.

She requires authorization for the following evaluations (Inventory Management): Material
documents, posting and reversal documents and archived documents for the material, stock
overview, warehouse stock, provision stocks and so on, availability overview, plant overview, and
purchase orders.

She requires authorization for the following evaluations (Controlling): Variance analysis, work in
process, planned costs, actual costs, target/actual comparison (variance categories), production
version: Line items actual/variance
© SAP AG
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Demand Management and MRP in R/3:
Course Objectives
At the conclusion of this unit, you will be able to:
 Create a master production plan in R/3 on the
basis of sales orders and planned independent
requirements (non-sales-order-based planning).
 SAP AG 2004
© SAP AG
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
The planned independent requirements from R/3 Demand Management or the sales orders from
Sales are the starting point for planning in Repetitive Manufacturing. Depending on your production
strategy, the planned independent requirements from Demand Management can be consumed by
sales orders. However, other requirements can also be taken into account (for example, stock transfer
requirements such as purchase requisition releases, purchase order releases or forecast delivery
schedules, or dependent requirements at assembly level). If these requirements are not covered by
warehouse stock, the system creates planned orders. These planned orders constitute the master plan.

Production quantities can be created in a number of ways:
 The production quantities can be created automatically in R/3 Material Requirements Planning
or Master Production Scheduling. Through use of quota arrangements or by setting the alternative
selection indicator in the material master, the system can automatically determine in the MRP run
which production version (and therefore which production line) is to be used to produce the
production quantities (automatic allocation of planned orders to production version). It is advisable
in many cases to check and/or postprocess the planning using the R/3 planning table.
 You can also manually assign the planned orders to specific production versions from the R/3
Repetitive Manufacturing planning table (REM planning table).
 You can also create planned orders manually in the R/3 REM planning table and/or assign them
directly to production lines as appropriate.
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
Make-to-stock production: You can use Repetitive Manufacturing for make-to-stock production.
This means you produce products with no direct reference to sales orders. The planned independent
requirements from Demand Management are used as the basis for planning. Depending on your
production strategy, the planned independent requirements from Demand Management can be
consumed by sales orders.
The same product is produced repeatedly over a substantial period of time. The product is not
produced in lots. Instead, a total quantity is produced in a certain period at a certain rate. Products
pass through production in a relatively steady flow.
Sales orders are delivered from stock.

Make-to-order production (sales order-based production) You can use Repetitive Manufacturing
for make-to-order production. This means you produce products with direct reference to sales orders.
The products are stored in the individual customer stock. Sales orders can be processed separately. A
planned order is created with direct reference to the sales order. Production is therefore controlled
using sales orders. The quantities produced cannot be swapped between the individual sales orders.
The produced quantities are stored specifically for the individual sales order (individual customer
stock) and not in the anonymous warehouse stock. If you use variant configuration, you can plan and
manufacture configurable materials using make-to-order repetitive manufacturing.
Sales orders are delivered from individual customer stock.

Prerequisite: You use the strategy group in the material master record to control whether you want
to use make-to-stock or make-to-order repetitive manufacturing.
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Line Loading in R/3: Course Objectives
At the conclusion of this unit, you will be able to:
 Assign production quantities to production lines
in R/3 (also considering the capacities)
 Print out the master plan for production from R/3
(production list).
 SAP AG 2004
© SAP AG
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Assigning Production Quantities to Lines
R/3
Production line 1
Production line 2
Material A
Automatic assignment in MRP or manual assignment in the R/3 planning table
 SAP AG 2004

You must decide which production version (for example which production line) is to be used to
manufacture the production quantity.

The planning table is available for manually assigning the planned orders to the production lines or
for postprocessing those planned orders that were automatically assigned. That is, in the planning
table you can assign the production quantities (planned orders) to a production version and therefore
to a production line.
© SAP AG
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
If a material is only produced on one production line and the production version is therefore only
valid for the date and lot size range, the planned orders can be automatically assigned to the
production version (and therefore also to the production line). This is done by means of the
alternative selection indicator in the material master.

If several production versions exist for a material which are valid according to date and lot-size
range, the MRP run assigns the first valid production version it finds. Therefore, it only makes sense
to automatically assign to production versions using the alternative selection indicator if a production
version already exists that is valid for the date and lot-size range.
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MRP: Automatic Assignment Using Quota
Arrangements
Scenario
- Material A can be produced on two production lines.
- One line is preferred. Planned orders should first be assigned
to the preferred line. The preferred line has a
quantity restriction (e.g. 2400 pieces per week)
- The remaining quantity should be assigned to other lines
or allocated by quota to other lines.
Material A
Week 1
Week 2
Line 1
Line 2
2400
200
2400
400
Planned orders
2600
2800
 SAP AG 2004

Using quota arrangements, production quantities (planned orders) can be automatically assigned to
the different production lines during the MRP run.

Scenario: Suppose for example, production lines 1 and 2 are available to manufacture a product. On
production line 1 the quantity is restricted to a maximum of 2400 pieces per period. During the MRP
run the quota arrangement can automatically assign a maximum of 2400 pieces per period to
production line 1 and the remainder to production line 2.

Using quota arrangements, planned orders for the same material which have already been assigned to
the preferred production line are taken into consideration: Extending the above scenario, assume that
during a certain period, a planned order of 2200 pieces has already been assigned to production line
1 and then an order of 300 pieces is added on top of that. The MRP run generates two planned
orders. The first planned order is for 200 pieces and is assigned to line 1 (to which 2400 pieces have
been assigned). The second planned order is for 100 pieces and is assigned to line 2.

The quota arrangement procedure, however, does not take planned orders into account that have
already been assigned to the same production line but are for different materials. Planned orders
assigned by quota arrangement may therefore need to be revised in the planning table.

You can also execute a percentage distribution of planned orders to the production lines. You can
also combine the percentage distribution procedure with the maximum release quantity procedure.
© SAP AG
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
Scenario: Two production lines are available to manufacture a material - line 1 and line 2. On
production line one, quantity restrictions apply (for example, a maximum of 2400 pieces per period).
A quota arrangement can be created to assign a maximum of 2400 pieces per period to production
line 1 and the remainder to production line 2 in an MRP run.

Prerequisites:
 Material master (MRP view): Quota arrangement is activated by MRP (Quota Arrangement Usage
field= 3).
 MRP menu: Quota Maintenance. The full range of quota arrangement functions are available.

In the above example, both quota item 1 and quota item 2 use the procurement type Internal
Procurement and special procurement type In-House Production. Priority 1 stipulates that a
maximum of 2400 pieces (Maximum Release Quantity) per one week (Quantity = 1, Period = W) is
to be assigned to production version 0001. As priority 2, the remaining quantity should be assigned
to production version 0002 (second quota item). In the above case, production line 1 is entered in
production version 0001 and production line 2 is entered in production version 0002.

With a simple approach, the smallest period you can use for the maximum release quantity is
"week". However, you can maintain maximum release quantities per day by choosing the period
Planning Calendar and creating a planning calendar with daily periods.
© SAP AG
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Introduction to the R/3 Planning Table
Plant
1200
Period of examination
Start
End
Bucket
Selection by production line
Production line
WkCtr hierarchy
line3
Nodes
Selection by materials
Material
Product group
Class
MRP controller
Class type
Scheduling/Capacity evaluation
Rate-based plng
Detailed planning
X
Capacity planning
Sequencing
Prod./basic dates 1
Sched. strategy 2
 SAP AG 2004

The planning table is compiled according to the selection you make in the initial screen.
 Using Selection by production line and specifying a production line provides an overview of all
planned production for the production line specified.
Here, you can also maintain the production line as a line hierarchy. Then, in the planning table,
you can plan production on the individual line segments of the line hierarchy.
To be able to work with the production line selection criteria in the planning table, you must
specify a work center (production line) in the production version of the material master record. A
minimum of one operation in the routing should be carried out on this work center.
 Specifying a single material under Selection by materials provides an overview of the entire
production for that material.
 Specifying a single MRP controller Selection by MRP controller provides an overview of the
entire production for that particular MRP controller.
 The Detailed line selection function in the control screen area (not shown on the above slide)
determines all materials for the production line and checks on which other production lines they
could be manufactured.
 If you select the Capacity planning field in the scheduling area, the system displays the capacity
data of the selected production line in the planning table. You can display capacity requirements at
a Rate-based planning or Detailed planning level.
 If you select Sequencing in the scheduling area, you can use the planning table combined with
Sequencing (see Planning and Control in Takt-Based Flow Manufacturing in the appendix).
© SAP AG
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Planning in REM Using the R/3 Planning Table
Capacity data
Line 1
Reqmt
Available
Line 2
Reqmt
Available
Material data
In this segment, you can
4.9.2003 5.9.2001
monitor the capacity
Un
Due
%
hr
hr
%
hr
hr
0
0
16
0
0
16
100
16
16
0
0
16
Un
Due
4.9.2003
Material A
Reqmt
Available qty
pc
pc
Production line 1
Production line 2
Not yet assigned
pc
pc
pc
200
0
load utilization of the
50 production lines
8
16
Pegged reqmts
150
display:
24
Material A: 8 h
16
Material B: 16 hr
5.9.2001
In this section, you can assign
the quantities to the
production lines
100
200
100
200
100
50
150
0
200
Assignment mode
 SAP AG 2004







The planning table enables the work scheduler to process the master plan. You can check the
production quantities at a glance, change it if required and create new production quantities (planned
orders). You can also determine the capacity load utilization of the production line as well as the
product's availability situation. Capacity pegging can be carried out by double clicking on capacity
requirements.
Since in Repetitive Manufacturing, you plan on a quantity and period basis, the display in the
planning table is also based on quantities and periods. The planning period (buckets) for the columns
can be chosen as necessary - shift, daily, weekly, monthly or planning calendar period buckets are
available.
In the assignment mode, you can assign the production quantities (planned orders) to a production
version and therefore to a production line. If this has already been executed in the MRP run, you can
also change assignments that have already been made. Planned orders that are manually assigned to a
production line receive the order type PE (run schedule quantity) and are usually firmed. You can
limit the firming procedure using the repetitive manufacturing profile per material. Here, you can use
a planning time fence or you can deactivate the firming procedure altogether.
Various key figures, such as the range of coverage and the available quantity, can be displayed in a
separate lines. It is possible to define the display order of these key figures. These settings can be
saved per user.
Clicking on the Material overview key results in a separate material overview which displays the
current status of exception messages and the days' supply.
Changes made to the planning table are not recorded in the database until you save.
Note: A customer exit (enhancement M61X0002) is available if you want to display extra rows
(such as the calculation of your own days' supply) in the planning table (material data table). You
can use the customer exit PTRM0001 to change the text column in the planning table. You can
change the existing lines and adjust them to your requirements.
© SAP AG
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
Lead time scheduling: If you access the planning table using the selection Detailed planning or Ratebased planning, the planned orders are scheduled using the production rates in the routing (that is,
the runtime of the planned order is calculated using the production rate in the routing combined with
the planned order quantity). The capacity load of the production line is calculated from the capacity
requirements created via the routing taking into account the planned order quantity and the operation
times. These are compared with the available capacity of the production line (standard capacity or
shift program). To calculate the capacity requirements, the system selects the routing which is
entered in the production version of the material. Therefore, for each material you can define a
different production rate.

If you use Detailed planning, the system reads the routing in the Detailed planning row of the
production version. The capacity requirements created in the planning table are saved at detailed
planning level.

If you use Rate-based planning,the system reads the routing in the Rate-based planning row of the
production version. The capacity requirements created in the planning table are saved at rate-based
planning level.

To be able to execute automatic scheduling in the planning table, the following conditions must be
fulfilled:
 The Capacity planning indicator in the initial screen must be set.
 The production version must specify on which production line the material is to be manufactured.
This production line must also be used in the routing.
© SAP AG
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Planning Table: Planned Orders Visualization
Capacity data
Line 1
Requirement
Av. capacity
%
hr
hr
Mon
Tue
Wed
0
0
16
100
16
16
0
0
16
... or display by Order finish date
Display by production finish date
Material data
Material A
Production line 1
pc
480
OS
PS
480
OF
PF
OS = Order start date for planned order
PS = Production start date for planned order
Float before and after production in this example = 0
Production rate according to routing: 30 pieces per hour
OF = Order finish date
PF = Production finish date
 SAP AG 2004

Scheduling determines start dates (order start date, production start date) and finish dates (order
finish date, production finish date) of planned orders. It may happen that a planned order runs over
several periods. Here, the finish date of the planned order determines the period in which the total
planned order quantity is displayed in the planning table.
Where the production finish date and the order finish date fall in different periods (for example, in
the day shift in the planning table), the Prod./basic dates field in the planning table determines which
date the entire planned order quantity is to be shown.

In scheduling, the order finish date (availability date) always falls on the next morning (because
basic date determination in the planning is exact to the day and the order finish date specifies the
availability date), while the production finish date (exact to the time) falls in the course of the
previous day.
In planning, components are staged at the order start date or at the time of particular activities. If you
require the dependent requirement for the component staging to fall on the same day as the
availability date for the assembly (order finish date), you can enter an in-house production time of 0
days in the material master.
© SAP AG
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Period-Based Planning in the R/3 Planning Table
In this section, you can:
Capacity data
Line 1
Requirement
Av. capacity
Line 2
Requirement
Av. capacity
UoM Due
%
hr
hr
%
hr
hr
0
0
16
0
0
16
4.9.2001
100
16
16
0
0
16
Material data
UoM Due
Material A
Requirements
Available qty
pc
pc
Production line 1
Production line 2
Not yet assigned
pc
pc
pc
200
0
4.9.2001
 Assign production quantities
to production lines
50 Enter new production quantities
8
16 Create new quantities according to the
150 production rate (line filling)
24 Create additional orders for capacity load
16
utilization over 100%
 Increase production quantities
 Oversee the capacity load utilization on
the production lines
100
200
100
200
100
50
50
0
0
In this section, you can process
the following operations:
 Planned orders
 Production orders for discrete manufacturing
 Process orders for process manufacturing
 SAP AG 2004

The planning table enables period-based planning.

Using the function Quantity by production rate/line filling, the system creates the maximum possible
production quantity in the selected period (Caution: Do not use in connection with assignment
mode!). The system calculates the maximum possible production quantity using the work
center/routing data you maintained or using the production rate you maintained in Line Design.
(Function is only available for visualizing planned orders by production dates).

In addition to planned orders, the planning table can display and process production orders for
discrete manufacturing and process orders for process manufacturing. Planned orders for nonrepetitive manufacturing materials can be directly converted into production orders using the
Convert Quantities function in the planning table. The system then shows the row PR.ORD on the
planning table where you can view these orders. To change these production orders, you must exit
the planning table and then access it again. You can change the production and process orders by
branching from the planning table to the order data. To do this, simply double-click the order. Here,
you can change the quantity, dates (only basic dates), scheduling type, and storage location. From the
dialog box, you have the option of branching to the following maintenance transactions of the
production order: Change components, change header data of the production order, change
operations, release production order, schedule production order. Any changes also update the
capacity data, the production orders appear in the capacity planning table as bars. In the capacity
planning table, you can dispatch or change the production orders.
Mass change functions such as distributing by shifts for production and process orders are not
possible from the planning table however.
© SAP AG
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
Prerequisites for displaying production and process orders in the planning table:
 Valid production versions in the material master with a routing at detailed scheduling level, no
repetitive manufacturing material!
 The repetitive manufacturing profile 1000 (Repetitive Manufacturing with partial orders) in
combination with a repetitive manufacturing indicator (processing up to and including SAP R/3
3.1) are no longer required for displaying production orders in the planning table. See Notes
104627 and 215256 when upgrading from SAP R/3 3.1 to a later release.
© SAP AG
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Planning Table: Additional Functions
 Multilevel quantity planning and capacity requirements
planning in the planning table (by selecting the finished
product and assemblies, for example, by selecting Work
center hierarchy or MRP controller: Updating the
component requirements)
 Representation of various periods (day, week, user-defined
period split)
 Traffic lights in the material overview in the planning table
(range of coverage display, exception messages)
 Transfer data to Excel
 Save user-specific selection criteria in the planning table
and the visualization in the planning table
 SAP AG 2004

Updating the component requirements: The system updates the requirements and available
quantities from components produced in-house, if you have changed the production quantity of the
assembly in the planning table. In this way the planner can recognize whether sufficient components
are available. If necessary the planner can react and increase the production quantities of the
components in the planning table. Prerequisite: When you enter the planning table you have
selected both the assembly as well as the components produced in-house (lower-level assemblies).
You do this by entering the planning table via MRP controller (if the MRP controller is responsible
for both the assembly as well as the components), or via the product group (in this case you have
created a product group for the assembly and the components), or via the work center hierarchy (if
you select via the work center hierarchy as well as the assembly production line and the component
production line, on which the assembly and components are produced).

User-specific settings in the planning table: You can make and save user-specific settings in the
planning table (which rows should be shown in which order, determine the width of text columns
and matrix columns, and so on).

With the user-defined period split in the planning table you can set the display of the periods which
you are planning. You can set how many days should be displayed in shifts, how many weeks in
days, and how many weeks should be displayed. You can also specify whether days are displayed
with date only or also with weekday.

Transfer data to Excel: You can transfer the planning table data to Microsoft Excel for evaluation
and printing.
© SAP AG
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
Use: Lead time scheduling can be executed immediately when planned orders are manually created
or changed in the planning table. You can set the scheduling strategy in the initial screen of the
planning table:
 In the scheduling strategy Backward, the order is scheduled backwards from the end of the period.
The system determines a start date which will be sometime during the course of the day.
 To ensure that planned orders start at the beginning of the day rather than sometime during the
day, you can select the strategy Backward, then forward from the start of the period. The start
date of the planned order is then fixed at the beginning of the day (the beginning of the standard
available capacity or the beginning of the shift) and switched to forward scheduling in order to
determine the new end date.
 In forward scheduling, the system takes the start of the period in which the production quantity
was entered as the start date and works forward to determine the end date.

For backward scheduling, either the order finish date or the production end date can be set at the end
of a period as required. For forward scheduling, either the order start date or the production start date
can be set at the beginning of a period as required. For both forward and backward scheduling, the
Prod./basic dates field controls which date is taken.
© SAP AG
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
Scheduling determines start dates (order start date, production start date) and finish dates (order
finish date, production finish date) of planned orders. It may happen that a planned order runs over
several periods. Here, the finish date of the planned order determines the period in which the total
planned order quantity is displayed in the planning table. Where the production finish date and the
order finish date fall in different periods, the Prod./basic dates field in the planning table determines
which date the entire planned order quantity is to be shown.

The complete order quantity of a planned order is displayed once, either in the period containing the
order finish date or the period containing the production finish date. To display when the individual
quantities are actually being manufactured, you can use the Quantity display function in the Orders
view to switch to the Distributed view or the Orders/distributed view. The Orders/distributed view
displays both the total quantity for the finish date (order finish date, production finish date) and in a
separate line, the quantities distributed to individual periods.
How planned order quantities are distributed between the individual periods depends on the entry in
the Prod./basic dates field. If you choose Production Dates, the planned orders are divided up
equally between the production start and the production finish dates (for the planning operation). If
you select Basic Dates, the planned orders are divided up between the order start and the order finish
dates according to the distribution function from the production version.
© SAP AG
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
Use: Planned orders can span several days. This can occur with a large quantity or as a result of
entering production quantities directly into the planning table (for example on a weekly basis). The
production quantity of one or more periods can be divided into individual planned orders to be dealt
with per day.

There are two options for the daily splitting of planned orders:
 Daily splitting per order: The system splits the order quantity in the same way as the function
Display Quantity: Split View, in that it splits the production quantities between the days within the
production dates taking into account the available capacity of the production line. Distribution is
carried out within the time it takes for an order to be manufactured and is determined by the
available capacity.
The system generates a planned order for each day and deletes the already existing planned order.
The splitting does not take into account the capacity load of the production line.
 Even daily splitting: The system distributes the whole production quantity for a period taking into
account the available capacity that you have maintained for the production line.
The distribution takes place within the period that is marked by columns.
The system generates a planned order for each day and deletes the already existing planned order.
The splitting does not take into account the capacity load of the production line.
 If you access the planning table using the basic dates and not using the production dates, you can
only use the Even Daily Distribution option. In this case, the equal distribution uses the splitting
function defined in Customizing for Repetitive Manufacturing (work step Planning).
If you access the planning table using production dates, the system directly executes Daily
Splitting per Order and Even Daily Splitting, and does not use the splitting function (distribution
in this case is even).
© SAP AG
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
Use: When working with larger orders whose validity period spans several shifts, the planned order
can be divided into individual planned orders per shift.
You can use the function shift splitting to split a planned order that spans four shifts, for example,
into four new planned orders. The original planned order then no longer exists.

The same functions are available for shift splitting as for daily splitting: Splitting per Order and Even
Splitting.

Shift quantities can be changed or created directly in the Shift overview of the planning table.

Prerequisite for shift splitting and shift planning in the planning table:
 In order to use shift planning in the planning table, Production Dates must be specified in the
Prod./basic dates field in the initial screen of the planning table. Since basic dates are only defined
to the day, you cannot use basic dates to view or manage quantities on anything other than a daily
basis.
 The planning table must be set in the Shift view.
© SAP AG
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
Use: Manually assigning planned orders to a production line results in these planned orders being
firmed. This function can be restricted to the planning time fence in the repetitive manufacturing
profile or can be completely deactivated. Sometimes a backlog of firmed planned production
quantities can result from machine malfunction for example. Since the MRP run does not in general,
delete or change firmed planned orders, this backlog of firmed orders will remain "in the past".

The planned production quantities lying before the current date are totaled and displayed as due
items in the first column of the planning table.

These firmed and due planned orders can be rolled forward into the future using the function
Move Quantities Along Time Axis. Here, the planned orders are actually displaced, they are not
deleted and recreated; the planned order numbers remain the same. Where necessary, these
production quantities can be distributed over a certain time period. If you access the planning table
using production dates, this kind of distribution is carried out using the predefined distribution
function from Customizing for Repetitive Manufacturing (work step: Planning).

As an alternative to the manual roll forward function, you can also move these fixed planned orders
in the past forward using the Automatic Roll Forward function (see Customizing for MRP). In this
case, the move takes place during MRP. You can use this function to delete firmed planned orders in
the past.
© SAP AG
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
You can display the days' supply in the planning table (for more detailed information, refer to the
MRP documentation):

The days' supply function indicates the number of days which a material's supply will last when
only taking current plant stock into account. The receipt days' supply function is similar, but also
makes allowances for certain definable receipts in addition to the current plant stock.

You can also display a requirement-oriented safety stock using the statistical days' supply
calculation. Statistically speaking, this means that the system does not consider the actual
requirements, but rather calculates the average of the daily requirements that fall within a specific
time frame. In the range of coverage profile, you define the minimum, maximum and the target range
of coverage as a planned number of days. The dynamic safety stock is then calculated on the basis of
the average daily requirement and the predefined range of coverage and is therefore automatically
adapted to requirements changes. It is completely available for planning. As the system uses average
requirements for this calculation, the requirements should be relatively consistently distributed. That
is, no drastic requirements variations should exist within the period to be used for this calculation.
Prerequisite: You define the parameters for the range of coverage profile in Customizing for MRP
and enter the range of coverage profile in the material master record.

The actual range of coverage specifies the number of days that the available quantity, on a
particular date or within a certain period of time, is sufficient to cover the requirements in the
following periods. The actual range of coverage is calculated by the system in the planning run for
all periods and is displayed in the period total display in the evaluations of MRP and in the REM
planning table. Note: Because the days' supply processing in R/3 is based on a day-specific planning
of the availability, means, for example, a days' supply of 2.31 days a mixed lot, in other words
coverage of the requirement by stock for 2 days, and on the third day only 31% coverage of the
relevant requirement.
© SAP AG
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Capacity Planning in Repetitive Manufacturing
SOP
Rough-cut plng profile
Rough-cut sched.
Rate-based plng
Rate-based sched.
Run schedule quantity
and/or
Rate routing or
standard routing
Entry in production
version
Detailed planning
Rate routing or
standard routing
Deailed scheduling
For Repetitive Mfg
SOP order
Production order
 SAP AG 2004

Capacity requirements can be created in Sales and Operations Planning (SOP), Repetitive
Manufacturing and discrete manufacturing. In general, capacity requirements are stored separately
according to the scheduling levels by which they were created. The capacity requirements created in
Repetitive Manufacturing (rate-based scheduling) are usually saved at the rate-based planning level
(if the routing in the production version is entered in the rate-based planning area, the capacity
requirements in Repetitive Manufacturing are saved at the rate-based planning level; if the
routing in the production version is entered in the detailed planning area, the capacity
requirements are saved at the detailed planning level). The capacity requirements created in
discrete manufacturing for production orders (detailed scheduling) are generally saved at the detailed
planning level. These capacity requirements can be displayed independently of each other in the
planning table.

Scheduling and capacity requirements determination for planned orders of a certain order type (for
example, LA and PE) can be carried out on a rate-based or detailed planning level (or both). This
determination is made in Customizing for MRP via the planning step in scheduling parameters. In
the standard system, scheduling and capacity requirements for planned orders of type PE are
activated on a rate-based planning level. For production orders, scheduling and capacity
requirements are specified on a detailed planning level. Note that the planning table can only display
capacity requirements of one scheduling level at a time.

Planned orders of type PE and production orders can be processed on a production line at the same
time. To enable this, both the Scheduling and Determine capacity requirements indicators for
planned orders should be set in Customizing. You must also enter the routing at detailed planning
level in the production version. Calling up the planning table with the Detailed planning key set in
the initial screen will display the capacity requirements of both the production order and the
Repetitive Manufacturing planned orders (order type PE) since they are both stored at detailed
planning level.
© SAP AG
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Planning Table and Capacity Planning Table
Capacity load
utilization
Table
100 %
Capacity reqmts
04.09.
05.09.
06.09.
Interactive, simulative
capacity leveling to create
a feasible capacity plan
07.09.
Time
Capacity load
utilization
100 %
Capacity reqmts
04.09.
05.09.
06.09.
Sequence for more than
one planned order
within one period?
07.09.
Time
Cap.
planning
table
 SAP AG 2004

To determine capacity requirements in the planning table, perform the following steps:
1. The system uses the production line in the production version as the basis for calculating the
capacity requirements.
2. The system searches for the operation with the production line in the routing.
3. The system calculates the capacity requirement according to the standard values maintained in the
operation and determines the production start and finish dates of the selected scheduling strategy
without taking the available capacity load into account.

Prerequisites:
 Initial screen planning table: button for detailed or rate-based planning, in accordance with the
setting that was defined in Customizing; Capacity planning indicator.
 Production version: specification of a production line.

Available capacity and capacity requirements are shown in units of time (e.g. hours), and capacity
load is displayed as percentages per period in the planning table for each production line. Capacity
dates are recalculated for every change made. The work scheduler thus has an overview of the
capacity status of his/her production lines and can react quickly to capacity overloads and underloads
in order to produce an appropriate capacity load utilization per period. At this stage in production
planning, there may still be several parallel planned orders per period (for example, per shift), since
the sequence of the planned orders has not yet been fixed. It is therefore possible for partial capacity
overloads to arise within a period, even though on average no overloads are recognized. For this
purpose, the production sequence can be determined at a later date using the capacity planning
table.
© SAP AG
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
In the planning table, planned orders can be assigned to production lines according to specific shifts.
It is therefore possible that more than one planned order is assigned to a production line within a
shift. Branching to the capacity planning table from the planning table enables sequence planning
for such planned orders. Planned orders assigned in the planning table appear in the bottom chart of
the capacity planning table in the form of bars. These planned orders can be dispatched in a defined
sequence by using the dispatching strategies in the planning table.

Assignment (planning table) versus dispatching (capacity planning table):
 Assigning a planned order determines the production version with which the material is to be
manufactured. This also specifies which production line is to be used. In Repetitive
Manufacturing, planned orders receive the order type PE (run schedule quantities) from the
assignment to the production version (production line).
 Assigned production quantities can be dispatched to their production lines in a specific sequence.
Dispatching to a production line firms a capacity load utilization in the planned order and fixes the
capacity load on the production line (Planned order is capacity planned indicator is set in the
planned order).

Changes made in the capacity planning table are immediately visible in the planning table and vice
versa. The user can switch between tables as required.

As a rule, the capacity planning table will only display the planning operation (see slide entitled
Planning Table: Lead Time Scheduling Using Routing with Several Operations).
© SAP AG
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
Production quantities can be dispatched in the capacity planning table using either of the following
two methods:
 manually using Drag&Drop
 automatically by flagging production quantities and then selecting the Dispatch function

Clicking the Strategy key enables you to select various dispatching criteria (the numbers correspond
to the above diagram):
1 Finite scheduling not active
2 Finite scheduling active
3 Planning direction backward
4 Planning direction forward

The Finite scheduling indicator enables finite scheduling to be carried out when dispatching
operations. Using the predefined date as a starting point, the system searches for a date with
remaining available capacity for the operation in the work center. The Plan. direction forwards
indicator determines if the direction of the search is forward or backward.

Setting the Plan. direction forwards indicator specifies that when an operation is automatically
dispatched, the system will search forwards from the predefined date to determine a possible
dispatch date. If the indicator is not set, the system will automatically search backwards.
© SAP AG
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
You can use the Strategy button to select further dispatching criteria (the numbers correspond to the
above diagram):
1 Dispatch at earliest point in time
2 Do not dispatch at earliest point in time
3 Dispatch and move the other run schedule quantities (insert operation)
4 Do not move the other run schedule quantities (this can lead to no dispatching taking place).

If you select the Dispatch at earliest point in time indicator, the system tries to dispatch the
operation as early as possible within the planning period. If the capacity is not shareable, the system
sequences the operations one after the other without leaving any gaps.

If the Insert operation indicator is set, the system will insert an operation to be planned in the
capacity planning table for the desired date. Operations that had previously been dispatched are redispatched and moved according to the planning direction, thereby leaving the sequence intact. In so
doing, your sequence is retained. If the moved operation should fall on a date on which a load has
already been assigned, the moved operation is scheduled either before or after this load, depending
on the planning direction

If a production line becomes overloaded, the production quantity can be automatically assigned to
another production line and rescheduled if the Reschedule with Production Versions indicator is set.
The system does not capacity dispatch the production quantity to the new production line, but instead
displays it in the lower chart of the capacity planning table. This function can only be performed
when the other production lines are already displayed in the capacity planning table.
© SAP AG
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Basis for Production Execution:
Printing the Production List from the R/3 Table
R/3
Line: Line3
Start date
Production
version
Total
quantity
Material Ord. no.
Start
time
Start
date
End
time
2.05.
Shift 1
0001
150
R-1110
0000018385
06:00:00
2.10.
13:50:00
0001
50
R-1111
0000018386
13:50:00
2.10.
18:00:00
2.05.
Shift 2
0001
150
R-1110
0000018387 14:00:00
2.10.
21:50:00
 SAP AG 2004

The processed planning table provides the basis for executing production. A list of the production
quantities can be printed to facilitate production. This can be done both for each production line and
shift, dependent on various selection criteria.

Alternatively, you can transfer the planning table data to Microsoft Excel for evaluation and
printing.
© SAP AG
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Planning Table: Lead Time Scheduling Using
Routing with Several Operations
 Scenario 1: Lead time scheduling using a routing with several operations (such as
reporting point backflush) - without using a line hierarchy
23
22
21
Displayed production start and finish date in the planning table and in the
capacity planning table
Float before production
as order buffer
Planning operation
10
Order start
date in
planned order
20
Production start
date in the
planned order
Routing
Operation Work center
10
20
30
Line4-11
Line4-12
Line4-21
Float after production
as order buffer
30
Production end
date in the
planned order
Order finish
date in
planned order
Routing has several
operations relevant to
scheduling)
 SAP AG 2004

Scheduling determines the start dates (order start date, production start date) and the finish dates
(order finish date, production finish date) of the planned orders. The dates of the individual
operations are also determined. In the planning table, the system only displays the dates of the
planning operation as well as the order start date and the order finish date of the complete order
(when you go to the detailed screen of the planned order from the planning table). The system does
not display the dates of all operations. In the capacity planning table, the system only displays the
planning operation. You can see the other operations when you access the planned order from the
planning table (Production Rates tab page). In the planning table, the system also only displays the
capacity requirements for the work center used to produce the planning operation (except when using
line hierarchies).

The planning operation is the operation from the routing with the work center which is recorded in
the production version in the Production line field. The work center for the planning operation must
also be used in the routing. The system then includes the operation with the scheduling work center
in the planning table for capacity planning.

If you change quantities and dates for the planning operation, the other operations are automatically
rescheduled using mid-point scheduling. In the planning table therefore, all the operations are
always scheduled but the system only displays the dates of the planning operation.

Note: The available quantity of a planned order is always displayed for the order finish date in the
planning table.
© SAP AG
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Planning Table:
Capacity Planning on Several Line Segments
 Scenario 2: Lead time scheduling using a routing with several operations
with a line hierarchy
Shop Floor Production
Line hierarchy
Line4
Line4-2
Line4-1
Line4-11
Line4-12
Line4-21
Capacity segments
Routing
Oper- Work
ation center
10
20
30
40
Line4-11
Line4-12
Line4-21
Line4-22
Control
key
Prod.
rate
Scheduling
Scheduling
Scheduling
Scheduling
30 pc / hr
15 pc / hr
30 pc / hr
15 pc / hr
Line4-22
Planning segment
Planning Table
Capacity data
Line4-12 (Line4)
Line4-22 (Line4)
Material data
%
%
4.9.
66,667
33,333
4.9.
Material A
Line 4-22 (Line4)
not assigned
pc
pc
90
 SAP AG 2004

Use: If you maintain the production line as a line hierarchy, you can use the planning table to
perform capacity-related planning for production separately for the individual line segments in the
line hierarchy. This kind of capacity planning is usually only performed if you normally use orderrelated manufacturing using production orders (discrete manufacturing). In this kind of environment
it is often difficult to align the individual stations with each other. Because the planning table can
also be used for production orders, you can use the line hierarchy to perform capacity planning for
more than one line segment. In repetitive manufacturing, it is usually easier to align the individual
stations of a production line with each other. For this reason, capacity planning is usually performed
for the entire line.

Prerequisites:
 You must maintain a line hierarchy in Line Design.
 You must define a certain line segment of the line hierarchy as the planning segment (definition
in the graphic of the line hierarchy). The planning segment is usually the bottleneck work center
and is used as the basis for lead time scheduling and capacity planning.
If you work with lead time scheduling, when you make any entries or changes, the system carries
out a mid-point scheduling for this line segment. That is, the operation with the planning segment
is the mid-point and is scheduled first. Starting from this point you schedule the operations before
and after.
Only the operation times of the planning segment are displayed in the planning table.
© SAP AG
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 Capacity requirements from other operations can also be displayed in the planning table
(capacity situation), as long as you have defined the corresponding line segments as capacity
segments in the line hierarchy graphic. This means that you can plan the capacity of each line
segment separately.
 You must also enter the line hierarchy in the production version in the Production line field. The
system automatically copies the planning segment of the line hierarchy to the production version.
This planning segment must be used in the routing.
 When accessing the planning table, enter the line hierarchy in the Production line field.
© SAP AG
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Special Planning Functions for MTO Repetitive Mfg
Course Objectives
At the conclusion of this unit, you will be able to:
 Use all the options available in R/3 for line loading
for sales order-based (MTO) Repetitive
Manufacturing.
 SAP AG 2004
© SAP AG
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Special Planning Functions for MTO Repetitive
Manufacturing
 Individual planning segment in the planning table
 Total requirements
 SAP AG 2004
© SAP AG
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Individual Planning Segment in the Planning Table
Capacity data
Line 1
Reqmt
Available
Individual Planning Segments
Material data
Material A
Sales order 1
Reqmts
Available qty
Production line 1
Not yet assigned
Sales order 2
Reqmts
Available qty
Production line 1
Not yet assigned
Un
Due
4.9.2003
%
hr
hr
0
0
16
100
16
16
Un
Due
4.9.2003
In this segment, you can
keep an eye on the capacity
load utilization of the
50 production lines
8
16
In this segment, you can
5.9.2001
assign the quantities to
the production lines
pc
pc
pc
200
0
pc
pc
pc
200
0
100
200
100
0
100
150
50
0
100
200
100
0
100
200
50
0
Assignment
mode
Decompressed or
compressed
display possible
 SAP AG 2004

Use: You usually use lead time scheduling (detailed, rate-based planning) in the planning table for
make-to-order repetitive manufacturing if you produce materials with higher lot sizes using make-toorder methods (for example, if you are a supplier to limited number of customers on the basis of SD
delivery schedules and you use make-to-order production techniques). The planning table is less
suitable for make-to-order repetitive manufacturing with lot size = 1 as too many individual planning
segments become confusing.

In mass production, you can also organize the assignment of the planned orders to the production
lines using quota arrangements (MRP menu) if a material is to be assigned to several production
lines. If the material is only to be assigned to one production line, you can accomplish the automatic
assignment using the alternative selection indicator = 2 (material master record).

In make-to-order repetitive manufacturing, production is carried out in individual planning
segments (MRP segments). Therefore, it is necessary to be able to display information such as the
available quantity of the individual planning segment in the planning table. You can display the
individual planning segment as follows:
• Aggregated display: The requirements, available quantities, production quantities and so on of
the individual planning segments are displayed in totalled quantities ("EPLAN").
• Disaggregated display: The requirements, available quantities, production quantities and so on
are displayed per individual planning segment. Then the planning table contains a title row with
various individual rows per individual planning segment.
This type of display only makes sense if you have many requirements within one individual
MRP segment. The display is not suitable for a large number of sales orders as too many
individual planning segments are confusing.
© SAP AG
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
If several planned orders are planned for an end product/assembly per day, these are exploded
individually and all dependent requirements are written individually to the database (various
requirements records). Both the extent of planning necessary, and the requirements on the database
can increase at a very fast rate.

For parts that do not need to be referenced to an order, it makes sense to summarize the dependent
requirements daily per component. This means that you can summarize the day's dependent
requirements per component to a total requirement with aggregated quantity.

Prerequisite:
­ Material master for end product/assembly: Repetitive manufacturing profile that authorizes the
creation of total requirements for all components (Total Requirements field).
­ Material master for components: If the Indiv./coll. indicator in the material master record of a
component is set so that individual requirements are created for the component, the system will
never create total dependent requirements. If you have selected Individual record in addition...
in the Group Requirements field or have authorized availability checks, the system creates an
individual dependent requirement for the component, in addition to the requirements total.
­ Total requirements however are not supported in make-to-stock repetitive manufacturing or
discrete repetitive manufacturing (production order processing).

You can display the components for which total requirements were created in a special list in the
planned order. The components list only includes components for which individual dependent
requirements were created.

It is important to recognize that the total requirements is not the same feature as the entry T in the
requirements grouping field (material master record). With this latter entry, you can group and
display various dependent requirements from one day in the MRP list, but this is for display purposes
only and is not saved on the database.
© SAP AG
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Demand Management and MRP with APO: Course
Objectives
At the conclusion of this unit, you will be able to:
 Use both R/3 and APO to create a production plan
on the basis of sales orders and planned
independent requirements.
 SAP AG 2004
© SAP AG
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
The planned independent requirements from R/3 Demand Management or APO Demand
Planning or the sales orders from Sales, are the starting point for planning in Repetitive
Manufacturing. Depending on your production strategy, the planned independent requirements from
Demand Management can be consumed by sales orders. However, other requirements can also be
taken into account (for example, stock transfer requirements such as purchase requisition releases,
purchase order releases, or forecast delivery schedules, or dependent requirements at assembly
level).
If these requirements are not covered by warehouse stock, the system creates planned orders. These
planned orders constitute the master plan.

Production quantities can be created in a number of ways:
 If you use APO, you can use APO Production Planning (APO PP/DS) to create the production
plans. Planning takes place using special heuristics adapted to repetitive manufacturing (you enter
these in the material master or the heuristics profile), where synchronous material planning and
capacity planning can take place. In contrast to the handling in R/3, this means that MRP and line
loading in APO do not mutually restrict one another. Instead, they are performed in combination
within production planning.
 The APO product planning table is suitable, for example, for manually reassigning quantities to
the available lines. Note: Since APO contains an automatic determination of the source of supply
(see Appendix), there is no need for an assignment mode in the APO planning table, because the
quantities are already assigned automatically after production planning. For this reason, you would
only need to perform a manual replanning where necessary.
 Furthermore, you can manually create planned orders in the APO product planning table, and
can therefore assign them directly to the production lines.
© SAP AG
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
Make-to-stock production: You can use Repetitive Manufacturing for make-to-stock production.
This means you produce products with no direct reference to sales orders. The planned independent
requirements from Demand Management are used as the basis for planning. Depending on your
production strategy, the planned independent requirements from Demand Management can be
consumed by sales orders.
The same product is produced repeatedly over a substantial period of time. The product is not
produced in lots. Instead, a total quantity is produced in a certain period at a certain rate. Products
pass through production in a relatively steady flow. Sales orders are delivered from stock.

Make-to-order production (sales order-based production) You can use Repetitive Manufacturing
for make-to-order production. This means you produce products with direct reference to the sales
orders. The products are stored in the individual customer stock. Sales orders can be processed
separately. A planned order is created with direct reference to the sales order. Production is therefore
controlled using sales orders. The quantities produced cannot be swapped between the individual
sales orders. The produced quantities are stored specifically for the individual sales order (individual
customer stock) and not in the anonymous warehouse stock. Sales orders are delivered from
individual customer stock. Using the Core R/3 System and from the production process models
(PPMs) in APO, no configurable products can be represented. Here, you could possibly use the iPPE
runtime object (iPPE-RTO).

Prerequisite: You use the strategy group in the R/3 material master record to control whether you
want to use make-to-stock or make-to-order repetitive manufacturing. The main strategy contained in
the strategy group is transferred to the APO system using the CIF (entry in the product master on the
Demand tab page in the Proposed strategy field). Note the different numbering procedures for the
strategies in R/3 and APO.
© SAP AG
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APO with PPM in Repetitive Manufacturing
R/3 activity
Maintain master data in R/3
and transfer to APO
APO activity
Make PP/DS settings
in APO
Transfer sales orders, planned
indep. reqmts, and stocks to
APO
Planning run with
REM heuristic
Goods issue
Material staging,
manufacturing,
backflush
If required, MRP for
subordinate bill of
material levels
Evaluation and
processing in the
product planning table
Transfer
procurement
suggestions to R/3
If required, automatic
plng of important
parts in APO
 SAP AG 2004

The APO system is not generally used as a standalone system. Rather it is used in connection with a
system used for processing the functions that extend beyond the planning processes (master data
system), such as SAP R/3.

When using the APO system with PPM to perform planning in repetitive manufacturing, actions are
also required in the R/3 system. The above graphic gives an overview of these actions.

The relevant master data from the material master is transferred to the APO product master. The
data from the BOM and routinf are summarized, in APO, in the PPM (production process model).
The R/3 lines (work centers) are mapped onto APO resources.
© SAP AG
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Line Loading in APO: Course Objectives
At the conclusion of this unit, you will be able to:
 Use the REM heuristics that cause automatic
planning of requirements, line loading, and
capacity
 In the APO product planning table, manually place
production quantities onto production lines, taking
account of the capacities
 Print the production list from the product planning
table
 SAP AG 2004
© SAP AG
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Planning Heuristics in Repetitive Manufacturing
Simultaneous quantity and capacity planning:
REM heuristics: Multiresource planning
SAP_REM_001
SAP_REM_002
Evenly
Primary resource
 Simple
 Template for your
own heuristics
 Complex
 Primary resource
has priority
(wave algorithm)
 SAP AG 2004

There are two basic heuristics available for APO planning in production in repetitive
manufacturing (REM heuristics; REM = Repetitive Manufacturing): SAP_REM_001 and
SAP_REM_002. These are particularly suitable for planning non-configurable products that can be
produced on common simply structured lines (Example: automatic fillers). You can use these
heuristics to simultaneously plan several resources (in repetitive manufacturing with PPM) or lines
(in repetitive manufacturing with iPPE): resources of type Line). Here you can take account of the
fact that products can be manufactured on alternative resources (lines), and can utilize the capacity of
the resources as you want within finite planning of the resources (lines). Note that this means
simultaneous quantity planning and capacity planning is possible.

The heuristic Multiresource Planning Even has been kept relatively simple (for example, it does
not consider a fixing horizon or a production horizon, and lot splitting is not supported) and is used,
for example, if several products are manufactured on several lines in repetitive manufacturing, and
you want the capacity utilization to be fairly even. In this case, no resource is favored over another
for cost, or any other, reasons. Use this heuristic in particular as a template for creating your own
heuristics with your own planning algorithms. Do not place them into your operative planning
without making any changes!

The heuristic Multiresource Planning Primary Resource is also used in scenarios where several
products are manufactured on several lines, however one line (the primary resource) should have
priority.

Note: The following restrictions apply to REM heuristics:

Only one operation per PPM. Where there are several operations, the system only considers the
operation for which the goods receipt occurs (output node).

Planning at only one MRP level.
© SAP AG
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Multiresource Planning Primary Resources:
Scenario
Max.
100 pc /week
and resource
Example Scenario
Product 1
Product 2
Only to L1, L3
Primary: L1
Only to L2, L3
Primary: L2
Resource L1
Resource L2
Resource L3
Week 1
Week 2
Week 3
Week 4
Week 5
Pld
260
ordr 250
230
190
Maximum
100
90
90
40
L1
L2
L3
L1
L2
90
50
30
L3
L1
L2
L3
L1
L2
L3
L1
L2
L3
Time
 SAP AG 2004

When you use the heuristic SAP_REM_002 ("wave algorithm"), the system attempts to utilize the
primary resource first, and then the alternative resource up to a given percentage.

When you use a PPM in the settings for the heuristic, the primary resource is set using the priority of
the mode.

The planning steps are as follows:
1) From the end of the planning period, finite planning backwards (backwards wave)
2) From the start of the planning period, finite planning forwards (forwards wave)
3) Finite (or infinite) planning of the remaining quantities

The example given shows the planned orders for the requirements for both products. At this stage
there are still "infinite resources" (the situation represents an infinite planning that is purely oriented
to the requirements). This results in an overload in weeks 1 and 5, since only 100 pieces per line and
interval are allowed (this corresponds to 100% capacity utilization).

The basic strategy for wave algorithms is always SAPREM2.
© SAP AG
TSCM32
5-47
Multiresource Planning Primary Resources:
Backwards Wave
Week 1
Week 2
Week 3
Week 4
Week 5
Pld
260
ordr 250
190
100
90
90
40
L1
L2
L3
Week 1
L1
L2
Week 2
L1
Maximum
100
L2
L3
90
50
30
L3
130
L2
L3
Week 3
L1
L2
L3
L1
Week 4
Time
Week 5
Pld
260
ordr 250
1)
10
90
100
90
90
40
L1
L2
L3
L1
L2
30
L3
L1
L2
L3
L1
30
50
80
L2
L3
2)
Maximum
100 100 100
L1
L2
L3
Time
 SAP AG 2004

The overload should preferably be removed in the current week. If this is not possible, any further
overload is distributed to the primary resources in the previous weeks. An additional product
prioritization is not implemented at the present time. The sequence during dispatching is a result of
the sequence of the requirements dates.

The "backwards wave" in the above scenario resolves the planning situation in weeks 4 and 5.

Weeks 2 and 4 show a standard situation. In contrast, there are overloads to be reduced in week 1.
© SAP AG
TSCM32
5-48
Multiresource Planning Primary Resources:
Forward Wave
Week 1
Week 2
Week 3
Week 4
Week 5
Pld
ordr 250
160
100
Maximum
100
90
90
40
L1
L2
L3
L1
Week 1
100
30
L2
L3
Week 2
L1
L2
L3
Week 3
L1
80
80
L2
L3
Week 4
100 100 100
L1
L2
L3
Time
Week 5
Pld
ordr
3)
1)
100
100 100 100
2)
10
90
60
100
40
L1
L2
L3
L1
L2
L3
40
30
90
L1
L2
100
L3
L1
80
80
L2
L3
Maximum
100 100 100
L1
L2
L3
Time
 SAP AG 2004

After the "backwards wave" has ended, the algorithm changes to "forwards wave": First, the system
distributes the planned order for product 2 to the alternative resource L3, until this resource is also
completely utilized.

The remaining overload in week 1 is distributed to the next chronological week. Any possible
overload that may then occur in week 2 is carried over with the "wave" into week 3, and so on.

In our example, the result is an evenly distributed capacity situation where there is a prioritized
utilization of the primary resource.

Depending on the settings for the heuristic, any remaining quantities for which there is no more free
capacity within the planning period are dispatched finitely or infinitely at the end of the planning
period, infinitely at the start of the period, or not dispatched at all.

When you use the heuristic, alert situations (exception messages) must occur.
- During finite dispatching at the end of the planning period, delays occur.
- During infinite dispatching at the end or start of the planning period, there is a capacity overload,
possibly in connection with delays.
- If you do not perform dispatching, the result is shortages, possibly in connection with delays.
© SAP AG
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5-49
Possible Steps in the Production Planning Run
Plant
Reqmnts Product A
Product B
Final assembly
Resource 1
A
P
Resource 2
A
Step 1:
Final assembly heuristic
Multiresource planning
Selection: Resources 1 + 2
Step 2:
Assembly manufacturing
heuristic Multiresource planning
Selection: Resources 3 + 4
Step 3:
Component procurement
Heuristic SAP_MRP_001
Selection: Products
P
Assembly manufacturing
Resource 3
Resource 4
Component procurement
Product A
Product B
 SAP AG 2004

Both SAP REM heuristics first perform the net requirements calculation. Afterwards they calculate
the lot sizes according to the settings in the product master, and generate scheduled APO planned
orders for the existing requirements, taking into account the free resource capacities available for
each period. Depending on the settings, the periods can be either days, weeks, or months. Users can
also define their own period splits.

To determine the requirement quantities and dates for the required components, the REM heuristics
perform a single-level explosion of the production process model. In this way they can determine the
dependent requirements to the directly subordinate BOM level.
The heuristics work exclusively with fixed setup times, and do not take into account a setup
dependent on a fixed sequence, such as is defined in the setup matrix for the PPM.
© SAP AG
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5-50
APO Product Planning Table: Construction
(Example)
Product planning table
Periodical resource view
22.06.03
22.06.02 24.06.03
24.06.02 25.06.03
25.06.02 26.06.03
26.06.02 27.06.03
27.06.02 28.06.03
28.06.02 01.07.03
01.07.02 02.07.03
02.07.02
Periodical
Periodicalresource
resourceview
view
Resource
WT-L100_1200_002
WT-L200_1200_002
Navigation tree
WT-L100_1200_002//Auslas....
Auslas....
WT-L100_1200_002
Reqmts
Reqmts
Available
Available
%
%
20,710
100
100
100
100
HH
HH
1,450
1,450
7,000
16,000
7,000
7,000
7,000
7,000
16,000
7,000
16,000
7,000
16,000
7,000
16,000
7,000
16,000
WT-M00_1000_002 / Auslas....
WT-L200_1200_002
WT-L100_1200_002 / Auslas....
%
%
%
Periodical product view
Periodical product view
T-F200
T-F1300 / Maxitec Computer
Available qty
Available qty
Range of Coverage
Range of Coverage
VP-BED / 20 / PLANNING
VP-BED / 20 / PLANNING
PL-ORD / T-F200
PL-ORD / WT-L100_1200_002
Total Reqmts/ Stock
PL-ORD / WT-L200_1200_002
Pc
Pc
Day
Day
Pc
Pc
Pc
Pc
Pc
Pc
100
24,641
100
100
100
100
7,000
7,000
7,000
7,000
16,000
50
7,000
8,000
50
7,000
16,000
50
100
22.06.02 24.06.02 25.06.02 26.06.02 27.06.02 28.06.02 01.07.02 02.07.02
22.06.03 24.06.03 25.06.03 26.06.03 27.06.03 28.06.03 01.07.03 02.07.03
200200
99.999
200200
129.999
200200
139.999
200200
149.999
200680
159.999
200680
169.999
200680
19
9.999
2001160
20
9.999
480
480
Total Reqmts/ Stock
Periodical product view
Charts
Shown
Periodical resource view
Periodical product view
Hidden
Alert Monitor
Product view individual elements
Chart selection
 SAP AG 2004

The APO product planning table (transaction: /SAPAPO/PPT1) enables the work scheduler to
process the master plan. You can check the production quantities at a glance, change it if required
and create new production quantities. You can also determine the capacity load utilization of the
resources as well as the product's availability situation. You can also execute a pegged capacity
where-used list.

The product planning table represents a tool with extensive functions, from which planning in APO
PP/DS can be performed and evaluated. There are several screen areas available that you can display.
Depending on your selection of the charts, you can adjust the product planning table to various tasks.

The navigation tree in the upper left displays the work scope of the product planning table. You can
use the tree to define which objects are displayed in the various views. It allows you, for example, to
form groups according to planner, product group, location, or resource. There are also subnodes for
in-house production and the bill of material. You can also hide the navigation tree.

At the lower left screen edge, you can Drag&Drop the charts (such as Periodic product view,
Periodic resource view, Alert Monitor, Quantity graphic, Periodic production view, and so on) you
want to display. You can show a maximum of three charts at one time (in addition, for example, to a
detailed view of the planned order). In the periodic views, there is also a menu for accessing the
typical characteristic lots (such as in the product view for fixing, and for the conversion indicator, in
the resource view for the operation time/downtime). Repetitive manufacturers might typically use the
following two charts (these charts are displayed on the right-hand side of the screen):
 Periodical resource view: Requirement and capacity of the resources (production lines) are
displayed. The system determines their percentage utilization.
 Periodical product view: The system displays the products for the resources, the order quantities
to manufacture in each period, as well as detailed information about dates and quantities. In this
area you can choose to perform manual or interactive planning.
© SAP AG
TSCM32
5-51

The APO product planning table is mainly used in repetitive manufacturing for period-oriented
planning. There are also numerous links to more extensive planning tools such as the Product View
(Single Elements), the Alert Monitor, or the Detailed Scheduling Planning Board, where you can
also display charts. As well as manual planning, you can also start planning heuristics and the PP/DS
optimizer from the product planning table.
© SAP AG
TSCM32
5-52
Manual Planning in REM Using the APO Product
Planning Table
Periodical resource view
Periodical resource view
WT-L100_1200_002 / Auslas....
22.06.03
25.06.03
26.06.03
27.06.03
28.06.02
100
Reqmts
H
1,450
Available
H
16,000
WT-L200_1200_002 / Auslas....
24.06.03
%
5.9.2001
In this section,
you can
monitor the capacity load utilization
on the resources.
01.07.02
16,000
16,000
16,000
16,000
16,000
16,000
8,000
16,000
%
Periodical product view
02.07.02
100
100
22.06.03
24.06.03
25.06.03
26.06.03
27.06.03
28.06.03
01.07.03
02.07.03
T-F1300 / Maxitec Computer
Available qty
Pc
200
200
200
200
680
680
680
1160
Range of Coverage
Day
9.999
9.999
9.999
9.999
9.999
9.999
9.999
9.999
VP-BED / 20 / PLANNING
Pc
PL-ORD / WT-L100_1200_002
Pc
PL-ORD / WT-L200_1200_002
Pc
480
480
Total Reqmts/ Stock
In this segment, you can
plan the quantities on
the resources
Periodical product view
 SAP AG 2004

As in the R/3 planning table, the APO product planning table enables manual line loading planning
with simultaneous capacity monitoring: The effects of the activities in the periodic production view
area can be monitored in the periodic resource view area.

The Periodic product view allows you to monitor (and sometimes make changes - see the
highlighted areas that are ready for input), for each product, the days' supply, receipts, requirements,
and preplanning. You can also aggregate the display and view detailed information. If you are going
to be working with strategies from In-House Production, then an individual customer segment (MRP
segment) is generated for each sales order, as in R/3. You can aggregate the display for these areas
using the Summary per product indicator on the Product 1 tab page in the user settings.

The Periodic resource view shows the absolute and relative utilization of the resources, and allows
you to display the orders sorted by product. As in the R/3 planning table, you can double-click on the
capacity load utilization to determine the pegged requirement.

Other views that might be relevant for repetitive manufacturers are, for example, the Alert Monitor
(for planning in exception situations), the Product view for single elements (the same as the R/3
stock/requirements list), the Detailed scheduling planning board (for time-specific sequencing),
and both of the product views.
© SAP AG
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5-53
Period-Oriented Planning in the APO Product
Planning Table
Produktplantafel
Ressource
WT-L100_1200_002
WT-L200_1200_002
In this section, you can:
22.06.02
Ressourcensicht
Ressourcensicht periodisch
periodisch
22.06.02 24.06.02
24.06.02 25.06.02
25.06.02 26.06.02
26.06.02
WT-L00_1000_001 / /Auslas....%
20,710
100
100
100
WT-L100_1200_002
Auslas....
%
Bedarf
H
1,450
7,000
7,000
7,000
Bedarf
H
1,450
Angebot
H 16,000
7,000 16,000
7,000 16,000
7,000 16,000
7,000
Angebot
H
WT-M00_1000_002 / Auslas....
%
WT-L200_1200_002
%
WT-F00_1000_002 / Auslas....%








27.06.02
27.06.02 28.06.02
28.06.02 01.07.02
01.07.02 02.07.02
02.07.02
100
100
100
100
100
100
7,000
7,000
7,000
7,000
16,000
7,000 16,000
7,000
7,000 16,000
7,000
16,000
8,000
24,641
50
50
50
100
Make user-specific saves
Also show your own subscreens
Go to messages and logs
(De)compress the display
Extend the selection subsequently
Enter new production quantities
Trigger automatic production planning
Maintain operating times/downtimes of
resources
 Perform sequencing
 Perform exception-based planning
Produktsicht periodisch
periodisch
22.06.02 24.06.02
24.06.02 25.06.02
25.06.02 26.06.02
26.06.02 27.06.02
27.06.02 28.06.02
28.06.02 01.07.02
01.07.02 02.07.02
02.07.02
Produktsicht
22.06.02
T-F200
T-F1300 / Maxitec Computer
Verfügbare Menge
St
200200200200200200200200Verfügbare Menge
St
200
200
200
200
680
680
680
1160
Reichweite
Tag
9121314151619
20
Reichweite
Tag 9.999
9.999
9.999
9.999
9.999
9.999
9.999
9.999
VP-BED / 20 / PLANUNG
St
VP-BED / 20 / PLANUNG
St
PL-AUF / T-F200
St
PL-AUF / WT-L100_1200_002 St
480
Summe Bedarfe / best
St
PL-AUF / WT-L200_1200_002 St
480
Summe Bedarfe / best
Teilbilder
Eingeblendet
Ressourcensicht periodisch
Produktsicht periodisch
Ausgeblendet
Alert Monitor
Produktsicht Einzelelemente
 SAP AG 2004

The product planning table supports user-specific saving of settings (layout/screen display,
subscreen selection, default profiles for subscreens, period splits, and so on). You can reset your user
settings using the report /SAPAPO/PT_DELETE_USER.

You can include additional customer screens by making entries in table /SAPAPO/PT_FRDYN in
the product planning table. The following BAdI (Business Add-In) is also available to show
additional lines in the Periodic product view: BAdI /SAPAPO/PPT_INFROW

With regards to efficiency of the available user interface, there are several options for
(de)compressing and (de)aggregating the display. You can compress single planning segments,
the one-line displays such as those in the periodic product view (per material), as well as the periodic
resource view and the separate (de)aggregation for preplanning, receipts, and requirements. (There
are also other different displays for quantities). As well as these options for vertical aggregation, you
can also compress the display across the time axis (horizontal): Choose Views - Periods to select and
modify the period split.

You can trigger a production planning from the product planning table. There are two different
process controls for interactive planning: Using the product heuristic, the products are planned with
the lot size procedure/heuristics that are stored in the product masters. Using the variable heuristic,
you can influence the planning result interactively by planning certain planning problems using other
heuristics stored in the product master (without changing the entries in the product master).
© SAP AG
TSCM32
5-54

As in the R/3 planning table, the product planning table allows you to display the days' supply (in
APO, this is even time-specific), as a yardstick to measure how long a material is available in
sufficient quantity to ensure production.

Note: Because the days' supply processing in R/3 is based on a day-specific planning of the
availability, means, for example, a days' supply of 2.31 days a mixed lot, in other words coverage of
the requirement by stock for 2 days, and on the third day only 31% coverage of the relevant
requirement. In APO there is no second-specific processing. For this reason the lots 2.31 can be
interpreted mathematically as a decimal number of the calendar days. The calculation is performed
by pegging area /area of assignment of receipt and issue elements), and is generally calculated from
(stock + receipts) / (requirement + forecast), where you define in Customizing which receipt and
issue elements the system should take into consideration.

You maintain the different possible categories of days' supply in Customizing and enter them in the
user settings, General tab page.
© SAP AG
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5-55
Basis for Prod. Execution: Printing the Production
List from the APO Product Planning Table
APO
Period: 02.05.2003 – 17.05.2003
Product: T-F1300
Start date: Activity
Location Resource
Quantity
Start
time
Start
date
End
time
WT-L200_1200_002
480
06:00:00
2.05.
13:50:00
WT-L200_1200_002
480
14:00:00
2.05.
21:50:00
2.05.
1200
2.05.
1200
 SAP AG 2004

The production list has its own transaction /SAPAPO/PPL1 in the Evaluations for Production
Planning.

You can print the product list from the APO product planning table To do this, select, for
example, the required resource and choose from the menu Edit - Periodic Views - Resource View Print Production List. ALternatively, you can print from the subscreen Periodic production view, if
you are using it. As in the R/3 planning table, you can also export data to MS Excel (Other
Processing Functions icon).

From the resource view, you can choose Other Processing Functions to print the resource schedule
(= production list):
© SAP AG
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5-56
Planning: Summary
 Options for creating a master plan (MRP/production
planning, planning table/product planning table)
 Functions in the planning tools in R/3 and APO
 Capacity planning in Repetitive Manufacturing
 Printing the production list
 SAP AG 2004
© SAP AG
TSCM32
5-57
Exercises
Unit:
Planning
Topic:
Demand Management and Requirements
Planning with R/3
At the conclusion of this unit, you will be able to
• Create a production plan in R/3 on the basis of predefined
sales quantities
The Maxitec PC is produced in your plant in Dresden.
You procure the assemblies for the PC before receiving a sales
order so that you can achieve shorter delivery times for the
customer. As the value added increases significantly at final
assembly, you do not carry out final assembly until you actually
receive a sales order.
In your role as the production planner, you plan for the future
requirements situation. To do this, you need to create the demand
program in the form of planned independent requirements
(forecast), on the basis of higher-level sales Demand Planning.
3-1
Your task is to plan the production of a personal computer. You are to use the
planning strategy “Planning without final assembly” so that assemblies for the
finished product are ready before sales orders are received.
Your first job is to maintain the master data required for producing the PC using the
production strategy “Planning without final assembly”. Then you can start creating
planned independent requirements.
3-1-1 In the material master record, in the MRP 3 view, check the strategy group
of the finished product T-F10## is set to planning without final assembly, or
change the setting to “Planning without final assembly” if required.
Make the following entries:
Plant:
1200
Strategy group:
50
Save if you have made any changes.
© SAP AG
TSCM32
5-58
3-1-2 Enter planned independent requirements for the finished product T-F10##
for your plant 1200.
Menu path:
Logistics  Production  Production Planning  Demand Management
 Planned Independent Requirements  Create
Field name or data type
Values
Material
T-F10##
Plant
1200
Planning period
W
Confirm with Enter.
In the next screen, choose the Sched. Lines tab. Enter a planned
independent requirement with the period W indicator (week format) with a
requirements date of next week (enter the calendar week in the form
Week.Year). Confirm any warning messages with Enter. The planned
quantity should be 3500 pieces.
The planned orders entered with period indicator W should be distributed to
individual days. You therefore set the D indicator (day format) in the Splt
column, confirm with Enter.
Confirm any warning messages with Enter.
Save.
3-2
A sales order is received in SD. Therefore, as an employee in SD, enter the sales
order for the finished product T-F10## in your plant 1200 into the system.
Menu path:
Logistics  Sales and Distribution  Sales Order  Create
Field name or data type
Values
Order type
OR
Sales organization
1000
Distribution channel
10 (Final customer sales)
Division
00 (Cross-division)
Sales office
1000 (Frankfurt)
Confirm with Enter.
© SAP AG
TSCM32
5-59
Field name or data type
Values
Sold-to party:
1171 (Hitech AG)
PO number
66##1
Required delivery date
Current week + 1, Thursday
Material
T-F10##
Quantity
800 piece
Choose Enter and confirm the dialog box that appears.
On the following screen (availability check), select the indicator Fixed Date (upper
left).
The Fixed Date indicator controls whether the delivery dates
and quantities confirmed after an availability check are fixed.
If the customer agrees to the delivery date or quantity
confirmed by the system, select this field. The system
forwards the requirement (confirmed quantity on the
confirmed date) to MRP.
If you do not set this indicator, the system forwards the total
requirement on the date originally requested by the customer
to MRP.
On which date (which weekday) could the system confirm the complete requested
quantity for the customer? Take note of when the total quantity is available in
production and also when the total quantity could be delivered to the customer:
____________________________________________________________
____________________________________________________________
On which week day will the total requested quantity now be available in your plant?
____________________________________________________________
Your customer wants the complete required quantity on one date. Therefore,
confirm the result of the availability check using the Complete deliv. indicator.
Save.
Note: The availability check is not the learning objective
of this course. Therefore, it is only used here to
demonstrate a complete process.
© SAP AG
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5-60
3-3
After you have created the planned independent requirements for the finished
product, the complete BOM structure for the PC must be planned in R/3 MRP.
Execute an MRP run for the finished product (T-F10##) in plant 1200:
Menu path:
Logistics  Production  MRP
Planning  Single-Item, Multi-Level
Enter the data from above in the initial screen and start the planning run by
choosing Enter twice.
3-4
Check the results of the planning run for the T-F10## finished product and TB10##l assembly, which are both to be produced using Repetitive Manufacturing.
Menu path:
Logistics  Production  MRP
Evaluations  Stock/Requirements List
3-4-1 Now look at the T-F10## end product:
Field name or data type
Values
Material
T-F10##
Plant
1200
Choose Enter to confirm, and analyze the results.
Is the sales order stock included in covering the sales order? Why (not)?
______________________________________________________
______________________________________________________
3-4-2 Check the current stock/requirements list for the T-B10## assembly by
entering the new material number in the Material field and confirming with
Enter.
Interpret the results.
Is the sales order stock included in covering the dependent requirements?
Why (not)?
______________________________________________________
______________________________________________________
Use the same method to switch back to the display of the T-F10## end
product.
© SAP AG
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5-61
3-5
Now, adjust the interface and functions of the current stock/requirements list for
further processing.
The current stock/requirements list is a very important tool in
the R/3 System for the daily work of the production planner.
Assign the navigation profile for repetitive manufacturing.
From the current stock/requirements list, choose
Environment  Navigation Profile  Assign
A dialog box containing several screens (tab pages) appears. The General Settings
tab page appears, where you enter the following values:
Checking rule for ATP display: PP
Navigation profile:
SAPPPREM01 (Repetitive Manufacturing)
Choose Save and note the changes in the user interface for your current
stock/requirements list.
What effect does the SAPPPREM01 navigation profile have on your current
stock/requirements list?
____________________________________________________________
____________________________________________________________
© SAP AG
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Exercises
Unit:
Planning
Topic:
Line Loading Planning with R/3
At the conclusion of this unit, you will be able to
• 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 R/3 planning table.
• Execute sequencing for planned orders in the capacity
planning table
• Print out the master plan for production (production list)
In your plant 1200 in Dresden, you produce the Maxitec-R 375
personal computer.
Different production lines are available for manufacturing the
assemblies and for final assembly.
You are the production planner for the production lines and you
also control the lower-level production lines. It is your job to
assign the production quantities to the production lines, taking
available capacity into account.
It is also your job to plan the production lines for final assembly
and the production lines for manufacturing the assemblies.
4-1
First, use the planning table to assign the planned orders to the production lines,
taking available capacity into account. First plan the quantities for final assembly
on the production lines:
4-1-1 First access the planning table using Selection by production line for the
final assembly T-L1## production line.
Use the tab pages on the initial screen of the planning table – if you have not
previously done so – to make detailed settings for the selection criteria.
On the Scheduling tab page, set the Rate-based plng indicator (so that the
system displays the capacity requirements you created using your rate
routings).
Also set the Capacity planning indicator so that you can see the capacity
requirements in the planning table.
In the Prod./basic dates field, enter Basic dates. On the Control data tab
page, activate the Line overview indicator.
Using the Line overview indicator instructs the system to display
other production lines in the planning table, if the materials produced
on the T-L1## production line can also be produced on other
production lines.
© SAP AG
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On the MRP segments tab page, choose:
Display of MRP segments: Disaggregated display. Your course instructor
will explain the meaning of this setting during the unit.
Save your entries in the initial screen of the planning table
for your user so that you do not have to repeat the selection
every time you access the planning table.
To do this, use the Settings  Save menu path.
Now choose the
Planning table button. The system displays another
dialog box. Here, select all listed production lines and confirm your
selection by choosing Enter.
You are now in the planning table.
4-1-2 Which order type do the planned orders have? To find out, double-click on a
planned order and look at the Order type field.
______________________________________________________
4-1-3 Work with the assignment mode to assign the as yet unassigned planned
orders for the sold-to party Hitech AG to the production lines. Select the
Not assigned row before you activate the assignment mode.
Now, assign the quantities per day: Place quantities on the first T-L1##
production line until this line is at full capacity. You can assign any
remaining quantities to the T-L2## production line.
© SAP AG
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Note: The planned orders for the planned quantities (order type VP)
cannot be assigned.
Reason: You selected the make-to-order planning strategy “Planning
without final assembly” for the T-F10## personal computer. In this
strategy, final assembly is not triggered until a sales order is received
(and not before). Using this planning strategy, the planning
quantities for the next two weeks only exist to make sure that the
assemblies (for example, the motherboard T-B10##) can be
produced to stock. This means that final assembly can be carried out
more quickly on receipt of the sales order. Final assembly is carried
out for each customer using make-to-order production.
There are other planning strategies (such as “Planning with final
assembly”, for which the planned orders can be created for the
planned quantities. You will use the strategy “Planning with final
assembly” in the next exercise. In this case, you can carry out final
assembly before receiving the sales order.
4-1-4 What order type do the planned orders have now that they have been
assigned to production lines? To find out, double-click an assigned planned
order and look at the Order type field.
______________________________________________________
Exit the planning table by choosing Save.
4-2
Now use the planning table to assign the quantities for the assembly production to
the production lines.
4-2-1 To do this, access the planning table again using Selection by production
line. Now, choose production line T-L3## on which the assembly
production is carried out.
Make the same selection criteria for the final assembly in the tab pages in
the initial screen of the planning table as you set during the Line Loading
Planning (on the Scheduling tab page, choose Rate-based plng and set the
Capacity planning indicator and the Basic dates entry. On the Control data
tab page, set the Line overview indicator).
Now choose the
Planning table button. The system displays another
dialog box. Here, select all listed production lines and confirm your
selection by choosing Enter.
You are now in the planning table again.
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4-2-2 Work with the assignment mode again, so that you can assign the as yet
unassigned planned orders for the T-B10## material to the production lines.
When making the assignments make sure that the daily capacity load
utilization for line T-L3## does not exceed 100%. You can place any
remaining quantities on the production line T-L4##.
No dependent requirements and therefore no planned orders are
visible for material T-B11##, since material T-B11## is not
contained in the BOM of the T-F10## personal computer. However,
material T-B11## can also be produced on production line T-L3##.
Exit the planning table by choosing Save.
4-3
In the next exercise, you are going to print the master plan for T-L3## production
line (production list). Production is carried out on the basis of this production list.
4-3-1 Display the production list from the Repetitive Manufacturing menu for
production line T-L3## (assembly production) in plant 1200. Call up the
master production schedule for the period commencing tomorrow to
Tuesday of next week.
However, we will not actually print out the list at this point.
4-3-2 In this exercise, have you triggered production by converting planned orders
into production orders?
______________________________________________________
4-4
The planned quantities from the planning table can be updated in a statistic, which
means you can evaluate and compare planning and actual figures later. In practice,
this is performed periodically as a background job.
Manually update the planned quantities for production line T-L3## for subsequent
evaluation:
Menu path:
Logistics  Production  Repetitive Manufacturing 
Evaluations  LIS Statistics  Update Planned Quantities
Field name or data type
Values
Plant
1200
Production line
T-L3##
Execute the report.
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4-5
Now look at the capacity planning table, which you can use in Repetitive
Manufacturing with R/3 if necessary.
In the capacity planning table, you can take the planned orders you already assigned
to a production line in the planning table, and schedule them in a particular
sequence. If, for example, you have several planned orders per period, you can only
display the total capacity load for each period in the planning table. In the capacity
planning table, however, you can schedule these planned orders at a specific time in
a period, making sure that the planned orders do not overlap within the period. The
capacity planning table also enables you to move planned orders to different dates
in a graphic (taking account of available capacity).
Start by accessing the planning table again, with Selection by production line for
production line T-L3##. Select the same parameters as in the previous exercise.
In the planning table, call the capacity planning table by choosing the
corresponding key or menu path.
Capacity Requirements Planning  Setup Graphic.
You can now use the capacity planning table to schedule planned orders in a
specific sequence. Use the mouse (drag and drop) to move the planned orders
(displayed as bars) from the lower to the upper part of the screen.
Note the following: You have already assigned the orders to production lines in the
planning table. All that you do in the capacity planning table is schedule the orders
at a specific time and plan their chronological sequence.
The changes you made in the capacity planning table are displayed in the planning
table, and vice versa.
Note on navigation and exiting the capacity planning table. If
you want to plan in both the planning table and the capacity
planning table, you should switch between the two tools
using the Planning Table button, or using the menu path
Goto → Planning Table to switch from the capacity
planning table to the planning table. To switch back again,
choose Capacity planning table or the menu path Capacity
Requirements Planning → Activate Graphic.
Do not change views using the Windows controls.
After you have finished sequencing, choose
to go from
the capacity planning table back to the planning table.
Choose
Capacity Requirements Planning  Exit Graphic.
to close the capacity planning table.
Exit the planning table. Do not save the changes that you made
© SAP AG
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Exercises
Unit:
Planning
Topic:
APO Production Planning Demand
Management with R/3
At the conclusion of this unit, you will be able to
• Perform demand management in R/3, which you can then use
as a basis for production planning in APO
Your company is planning to use an SCM system to plan
production quantities and production line loading. The planning
functions are to be tested using the PC T-F13##.
To prepare planning in SCM-APO, create a demand in R/3 by
creating planned independent requirements and a sales order for a
period of four weeks.
Note: In practice, you would not plan two materials from the
same enterprise area (such as T-F10## and T-F13## here) partly
in R/3 and partly in APO – especially if they are manufactured
using the same resources. For this course, the above procedure
(T-F10## = “R/3 material” and T-F13## = “APO material”) is
solely for demonstration purposes.
5-1
The integration relationships between R/3 and SCM-APO have been defined. In
R/3, first, check the relevant data in the material master record for your T-F13##
test material, plant 1200.
5-1-1 Is the indicator for repetitive manufacturing set?
______________________________________________________
5-1-2 Which repetitive manufacturing profile has been selected?
______________________________________________________
5-1-3 How many valid production versions have been created? Check this data for
consistency with reference to the routing and bill of material. Use change
mode (MM02) here.
______________________________________________________
5-1-4 Which production lines are scheduled to perform production, according to
the valid production versions?
______________________________________________________
______________________________________________________
5-2
© SAP AG
In R/3, create a forecast (planned independent requirements) for the T-F13##
personal computer in plant 1200.
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From the Demand Management menu, call up the transaction for creating planned
independent requirements. Select W for weeks as the planning period. Switch to the
Sched.Lines tab page and choose the planning horizon Current week + 4. Do not
enter a quantity. Enter D for a division by day in the Splt field. Confirm with Enter.
Enter the following planned quantities for the individual days of this week:
Weekday
Monday
Tuesday
Wednesday Thursday
Friday
Planned
quantity
600
500
100
500
300
Note: If this week contains holidays, leave out the corresponding
quantity/quantities.
Save these entries.
5-3
To check the consumption situation, a sales order will be considered, as an
example.
Menu path in R/3:
Logistics  Sales and Distribution  Sales Order  Create
Field name or data type
Values
Order type
OR
Sales organization
1000
Distribution channel
10 (Final customer sales)
Division
00 (Cross-division)
Sales office
1000 (Frankfurt)
Confirm with Enter.
Field name or data type
Values
Sold-to party:
1500 (Royal British Rail)
PO Number
66##2
Required delivery date
Current week + 5, Tuesday
Material
T-F13##
Quantity
10 pieces
Confirm with Enter and then Save the order.
© SAP AG
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5-4
Check the planning situation in R/3 for the current stock/requirements list.
5-4-1 Is the sales order in a separate planning area? Why (not)?
______________________________________________________
5-4-2 Has the sales order been settled by the planned independent requirement?
______________________________________________________
You will generate procurement elements for this plan in the
next exercise in the SCM system. Planning quantities (and
the sales order) are transferred from the R/3 System to the
SCM system using an appropriate active integration model –
as already mentioned.
© SAP AG
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Exercises
Unit:
Planning
Topic:
APO Production Planning Line Loading
Planning and Product Planning Table
At the conclusion of this unit, you will be able to
• Use the APO product planning table for planning in repetitive
manufacturing
• Use special heuristics for repetitive manufacturing, in order to
perform requirements planning and Line Loading Planning
based on algorithms (also considering finite resources)
• Print the production list from APO
The forecast that you created in R/3 will now be used in the SCM
system to perform requirements and Line Loading Planning.
In your capacity as production planner, you use the APO
production planning table to realize this task.
First, make settings for a main PP/DS object, the production
horizon.
6-1
In the SCM system, call the product master from the master data menu:
Field name
Values
Product
T-F13##
Location (Select)
1200
Select Change. You are now in the product master.
Choose the PP/DS view in the top right of the tab page. Change the value for the
PP/DS horizon to 40 days. If necessary, confirm the message to automatically
adjust the PP/DS horizon and save before leaving the product master.
© SAP AG
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6-2
Examine the product planning table in the SCM system, and set it up for your
work as a planner for repetitive manufacturing:
6-2-1 In the SCM system, call up the product planning table from the menu for
interactive production planning.
On the initial screen, choose Planning version 000 in a planning horizon
from today in 2 weeks until Friday of the current week + 6. Enter location
1200 and select the T-F13## product on the Product tab page.
Choose Execute (F8).
On the following screen, choose the SAPALL propagation range and
confirm with Enter.
(Note: If at this point, a dialog box appears before you access the actual
product planning table, select the variant PC_REM in the Selection field.
Save this as a user variant:
Variant description:
PC_REM##
Group## Standard
where ## is your group number. Confirm with Enter.
The product planning table appears.)
6-2-2 Select the Alert Monitor in the screen area for subscreen selection, and
move it using drag and drop to the Shown area. On the following screen or
in the “Settings” menu, choose the SCM320_001 alert profile (if necessary).
What is the situation in the screen area on the right side of the screen?
______________________________________________________
______________________________________________________
______________________________________________________
6-2-3 In the following exercise, you want to perform a manual Line Loading
Planning for the WT-L1##_1200_002 resource in the product planning
table using the alert monitor.
This should be performed at first without automatic consideration of the
available capacity, that is, infinitely. Select the Strategy button, use the F4
help to select the SCM320_001 strategy profile (infinite scheduling
backwards with direction change), and confirm your entries with Continue.
Now, carry out a test by performing Line Loading Planning manually. To do
this, enter planned order quantities directly onto the production line.
For each planning quantity, create the relevant planned order quantity
completely for resource WT-L1##_1200_002 for the day previous to the
relevant planned independent requirement. Confirm with Enter and note the
exception messages in the alert monitor.
During loading planning, note the existing sales order stock at the beginning
of production, and only cancel planning if the alert monitor does not issue
any messages at all, or if it issues overload messages.
© SAP AG
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Which types of exception messages are issued during your planning
activities (in the Description field)?
______________________________________________________
______________________________________________________
______________________________________________________
Delete your manual Line Loading Planning without saving. To do this,
choose the Refresh button and undo the changes.
6-2-4 Test the “wave algorithm” for automatic Line Loading Planning for both
production lines that are available, taking finite resources into account.
Choose Variable Heuristics. On the following screen, select the heuristic
Multi-resource Planning (Primary Resource).
The heuristic multi-resource planning (primary resource) is
always linked to the SAPREM2 strategy profile, which
supports finite scheduling (in other words, the actual
available capacity is included here).
On the Settings tab page, select the Only selected objects and Fix orders
fields. Enter a maximum resource utilization of 90%.
On the Products tab page, select your product T-F13## and copy it, using
the arrow, to the Selection for Planning area. On the Resources tab page,
proceed in the same way for the WT-L1##_1200_002 (primary resource)
and WT-L2_1200_002 resources.
Choose Execute Heuristic (F8).
Look at the Status Window and after planning has completed successfully,
go Back to the product planning table.
The concept of the multi-resource planning (primary
resource) heuristic is to plan more than one resource with all
the products that can be manufactured using these resources
and can be available for the requirements. As a result, the
system displays various products after the planning run.
Double-click on the product number to compress the
individual planning steps (when using the navigation tree,
you can also completely hide any products you do not
require).
Note the planning result for product T-F13##. Analyze the result using the
slides concerning this heuristic in your course materials.
© SAP AG
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Use keywords to describe how the result came about:
______________________________________________________
______________________________________________________
______________________________________________________
______________________________________________________
______________________________________________________
______________________________________________________
Do not exit the product planning table yet.
Note: If you execute a single-level planning heuristic, this removes
dependent requirements that you then have to plan yourself. It would be
advisable to avoid this during the exercise.
6-3
Now print the production list. In the periodic resource view, select the two lines
containing the planned resources.
In the periodic resource view, select Other Processing Functions to print the
resource schedule. Only select the period for your previous Line Loading Planning.
Execute the report.
However, we will not actually print out the production list at
this point.
Exit the production list by choosing Back. Save the planning results in the product
planning table before you exit the table.
Note: When you save, the planning data is posted in the SCM system and then
transferred to the R/3 System. You can perform additional processing (for example,
with regard to material staging, backflushing, evaluation) in the R/3 System.
However, this is not included in this test scenario.
Since your planning tests in the SCM system are now complete, you can exit the
SCM system.
© SAP AG
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Solutions
Unit: Planning
Topic: Demand Management and Requirements Planning
with R/3
3-1
3-1-1 Menu path:
Logistics  Production  Master Data  Material Master
Material  Change  Immediately
Field name or data type
Values
Material
T-F10##
Confirm with Enter.
In the dialog box that appears, select the MRP 3 view
Confirm with Enter and make the following entry:
Plant: 1200
Confirm with Enter.
Strategy group: 50
Save.
3-1-2 - No solution necessary 3-2
You can find both the dates in the date fields in the Complete deliv. area.
3-3
- No solution necessary -
3-4
3-4-1 The sales order stock is not included, because a sales order-based
manufacturing is present at end-product level (production in sales order
stock).
3-4-2 The sales order stock is included, because an anonymous make-to-stock
production is present at dependent requirement level (no individual
customer segments).
3-5
© SAP AG
By assigning the SAPPPREM01 navigation profile, the system displays buttons for
the planning table, material staging, backflushing, GR statistics, and target/actual
comparison. You can use these buttons to access various repetitive manufacturing
transactions directly from the stock/requirements list.
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Solutions
Unit: Planning
Topic: Line Loading Planning with R/3
4-1
4-1-1 Menu path:
Logistics  Production  Repetitive Manufacturing 
Planning Planning Table  Change Mode
Field name or data type
Values
Plant
1200
Production line
T-L1##
4-1-2 Before the planned orders are assigned to the production lines, the planned
orders have the KD order type (make-to-order).
The Order type field is located beside the Status field.
4-1-3 First activate the assignment mode that you can use for assigning quantities
to the production lines.
To do this, in the lower section of the screen entitled Material data, select
the row (Not yet assigned) for the “Hitech AG” sold-to party (make the
selection by selecting the button at the beginning of the row).
Then choose
(Switch on/off assignment mode ). A symbol appears at
the start of the row, signifying that you are in assignment mode for this row.
Now you can assign the planned quantities that are in the Not yet assigned
row to production lines.
Note for assigning: When assigning quantities, simply enter the various
planned order quantities in the respective columns for production line TL1##, choose Enter and check the capacity data in the upper section of the
screen.
4-1-4 The planned orders have now received the PE order type as a result of
being assigned to the production line.
© SAP AG
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4-2
4-2-1 Menu path:
Logistics  Production  Repetitive Manufacturing
Planning Planning Table  Change mode
Field name or data type
Values
Plant
1200
Production line
T-L3##
4-2-2 First activate the assignment mode that you can use for assigning quantities
to the production lines.
To do this, in the lower section of the screen entitled Material data, select
the row (Not yet assigned) for the material T-B10## (make the selection by
selecting the button at the beginning of the row).
Then choose
(Switch on/off assignment mode). A symbol appears at the start
of the row, signifying that you are in assignment mode for this row.
Now you can assign the planned quantities that are in the Not yet assigned row to
production lines.
Note for assigning: When assigning quantities, simply enter the various planned
order quantities in the respective columns for production line T-L3##, choose Enter
and check the capacity data in the upper section of the screen.
4-3
4-3-1 Menu path:
Logistics  Production  Repetitive Manufacturing  Planning 
Production List
Field name or data type
Values
Plant
1200
Start of period of examination
Tomorrow
End of period of examination
Next Tuesday
Production line
T-L3##
(Copy the remaining settings and execute the report)
Note: You can also print the production list from the planning table: Goto –>
Production List
4-3-2 No. Production takes place using planned orders.
4-4
- No solution necessary -
4-5
- No solution necessary -
© SAP AG
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Solutions
Unit: Planning
Topic: APO Production Planning
Demand Management with R/3
5-1
5-1-1 Yes
5-1-2 0001
5-1-3 There are two valid versions available. You can check their consistency in
relation to the routing and BOM using the Check button in the details for
the production version.
5-1-4 According to the line loading plan in the second production version, the
production lines T-L1## (for production version 0001) or T-L2## (for
production version 0002) are supported. These are also entered directly for
displaying the capacity requirements in the production version.
5-2
Menu path:
Logistics  Production  Production Planning  Demand Management 
Planned Independent Requirements  Create
5-3
- No solution necessary -
5-4
Menu path:
Logistics  Production  MRP  Evaluations  Stock/Requirements List
5-4-1 The sales order is not in a separate planning area because you are working
with the make-to-stock production strategy “Planning with final assembly”.
5-4-2 The sales order is settled by planning (the quantity of a planned
independent requirement is displayed in the stock/requirements list as
reduced by the quantity in the sales order).
© SAP AG
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Solutions
Unit:
Planning
Topic: APO Production Planning
Line Loading Planning and Product Planning Table
6-1
Menu path in the SCM system:
Advanced Planning and Optimization  Master Data  Product
Note: The detailed scheduling in this section is carried out using APO PP/DS
functions. The effective area of these planning functions is restricted to the
production horizon.
6-2
Menu path in the SCM system:
Production Planning  Interactive Production Planning  Product Planning
Table
6-2-1 - No solution necessary 6-2-2 The planned independent requirements created in R/3 and the sales order
for material T-F13## should be viewed as daily quantities in the Product
view periodic. Because no planning has yet taken place, there are no
capacity requirements. In the alert screen area, the system refers instead to
a shortage in connection with planning.
6-2-3 During manual line loading planning in this example, several alerts, such
as shortage, surplus, and resource overload are possible.
This exercise helps you learn that you can perform your manual planning
based on the dynamic exception messages.
© SAP AG
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6-2-4 The result of automatic line loading planning varies, for example, if there
are public holidays during the planning week, or if the algorithm prioritizes
resource 2. In principal, the following planning result is produced:
Avail.
50
50
Days’
supply
4
3
Planng
1
1
1
600-
500-
100-
300-
100
300
432
Resource 1
432
432
Resource 2
118
68
SuReq.
500-
68
10-
Keywords for interpretation:
o The comparison of the sales order (total requirements) with the
planned independent requirements is based on the date and time of
the requirements.
o A production line (here resource 1)is utilized with priority (as
specified in the algorithm parameters).
o The largest utilization of a production line is at 90%, in accordance
with the setting you made for the maximum utilization.
o The quantity already available (sales order stock) is included in the
first planning requirement. This means that there is a first
requirement of a total of 550 pieces for the previous day.
o
6-3
© SAP AG
Planning process: An infinite planning would result in exclusive
planning of the primary resource and a resource overload on three
production days.
Backward wave: Maximum utilization of the primary resource, the
rest will find remaining available capacity in the alternative
resource. Otherwise, they would find remaining available capacity
in the previous interval (no forward wave takes place in this
example).
- No solution necessary -
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Material Staging
Contents:
 KANBAN
 Storage Location MRP
 Pull List
 SAP AG 2004
© SAP AG
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Material Staging: Course Objectives
At the conclusion of this unit, you will be able to:
 Explain the various alternatives for controlling
material flow
 Carry out replenishment of components to the
production line, using the pull list
 SAP AG 2004
© SAP AG
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© SAP AG
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Material Staging: Business Scenario
 In your plant 1200, you produce the PC assembly
T-B10## on production line T-L3##.
 The components required to make the assembly
must be staged at the production line.
 SAP AG 2004
© SAP AG
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
John is responsible for planned orders in his area, material staging, KANBAN, backflushing,
operational method sheet, plant management (extra single role), cost center management (extra
single role), personnel management (extra single role), and quality management (extra single role).

He requires authorization for the following master data (display and change, if necessary):
Production versions, line design (work centers, rate routings, line hierarchy, line balancing,
operational method sheet), material master, material BOMs, production resources and tools, serial
number maintenance, documents (drawings and so on), control cycles (kanban and WM), supply
areas, delivery schedule, vendor, customer.

He requires authorization for the following planning transactions: Planning table, sequencing,
collective availability check, stock/requirements list, pegged requirements, stock overview,
production list.

He requires authorization for the following material staging transactions: Triggering material
staging, displaying material staging, stock transfer of components, picking, displaying logs.

He requires authorization for the following backflushing transactions: Collective backflush, final
backflush, reporting point backflush, KANBAN backflush, posting with correction
(activities/components), scrap backflush, separate backflush, reversal, postprocessing.

He also requires authorization for evaluations (production, inventory management and
controlling).
© SAP AG
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
In Repetitive Manufacturing, there are various options for controlling the material flow of
components to your production lines:
­ planning-based, using the pull list
­ consumption-based, using storage location MRP
­ KANBAN.
© SAP AG
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
In KANBAN, material flow is organized using containers stored directly in production at the
appropriate work centers. Each container contains the quantity of material required by that work
center personnel for a certain period of time. As soon as a container is emptied at the demand source,
replenishment is initiated. The supply source for the required material can be another place in
production, an external supplier, or a warehouse. The demand source can use material from other
containers until the filled container arrives.

The aim is that the production process is controlled by production itself, and that the employee has to
perform fewer manual postings. This self-management and the fact that replenishment elements are
created close to the time they are actually consumed means that stocks are reduced (replenishment is
only triggered when a material is actually required and not before) and lead times shortened.

KANBAN in summary: With KANBAN, material is staged where it is used. It remains there, in
small buffers, ready for use. Thus, material staging does not need to be planned. Instead, material
that is consumed is replenished immediately using KANBAN.

If KANBAN is implemented with the support of the R/3 system, transmission of replenishment data
can be automated: scanning the barcode on the KANBAN card suffices to transmit the data needed
for procurement and to post the goods receipt upon receipt of the material. If the supply source is a
production line, a run schedule quantity can be generated by leaving a blank. The backflush is then
executed using the goods receipt message for KANBAN.
© SAP AG
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Storage Location MRP
 Stock transfer within plant
 Procurement by another plant
 Special procurement
Stor. loc. stock
Issue storage
location 1
Reorder
point
Replenishment
quantity
Time
 Storage location MRP as manual reorder point planning
 Storage location MRP possible as material requirements planning
(when using MRP areas)
 SAP AG 2004

Material requirements planning is usually carried out at plant level. You can now, however, also use
storage location MRP. This means that the MRP run plans material requirements specifically for
the flagged storage location.
 Storage location MRP as manual reorder point planning (consumption-based MRP):
 Prerequisites: In the material master (MRP view), maintain the MRP indicator 2 (which causes
separate MRP for the storage location stock) for a specific storage location. Also enter a reorder
point and a replenishment quantity.
 This storage location stock is monitored automatically by MRP. If the reorder point is not met, the
storage location stock is automatically replenished. The system generates an order proposal
corresponding to the replenishment quantity, or a whole multiple of the replenishment quantity, in
order to make the total stock at the storage location greater than the reorder point. Inward
movements that already exist for the warehouse are taken into account when this is performed (as
with reorder point procedures at plant level). Stock in a storage location that is planned separately
is not included in the available stock at plant level.
 Storage location stock that is planned separately can be procured in different ways: Stock transfer
within a plant from storage locations that do not have separate MRP; Special procurement for
the storage location for which there should be separate MRP. This means that external or
internal procurement can be directly triggered for this special storage location; Procurement from
another plant.
 Storage location MRP as planning-based material requirements planning (when using MRP
areas):
 Storage location MRP areas summarize one or more storage locations into one organizational unit.
This unit is planned separately from the remaining plant and MRP areas during requirements
planning. You can assign different MRP parameters to a material for each MRP area.
© SAP AG
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
Use: The pull list controls the internal material flow of supplies to production. It is assumed that the
components required by production have already been produced in-house or procured externally, and
now simply have to be transferred from their current storage location to the production storage
location (material staging within the plant).

Activities: You access the pull list, for example, by calling up the production line. The system
determines the stock situation with the quantities that have already been initiated by the pull list and
compares these with the requirements that occur (dependent requirements, reservations). The
calculated difference equals the missing parts. Replenishment elements can be created for these
missing parts (material staging based on planning).
One method of staging components is direct stock transfer. If you trigger the component staging
from the pull list, the system checks whether the stock transfer can take place and locks the stocks at
the replenishment storage location. The stock transfer then takes place when you save; that means,
the system posts the goods receipt from the replenishment storage location for the components.
When you save, you can also print a list of these postings for warehouse personnel. This list states
the replenishment location, the target storage location and the quantity required. The list can then be
used to carry out the physical stock transfer.

Prerequisites:
 The issue storage location for the components must already be known; that means, the dependent
requirements of the planned order must already have a storage location. The system only displays
the requirements for which the issue storage location has been determined (in the BOM or in the
material master).
 In the initial screen of the pull list, choose the staging type Storage location level. You then access
the storage location view directly.
© SAP AG
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
Use: To use direct stock transfer in the pull list, you must enter the replenishment storage location
for each component. The replenishment storage location is the one from which components are
withdrawn to be transported to production; i.e., to the production storage location near the production
line. The replenishment storage location can be entered manually or can be determined by the system
using the stock determination function. Stock determination can refer to both unrestricted-use stock
and unrestricted-use consignment stock. Several storage locations can be entered. Stock
determination can run either online or in the background.

Batch determination: If a component is a material requiring batch handling, the system triggers
both stock and MM batch determination. You must therefore maintain the batch search procedure
(defined in Customizing for Logistics - General in the IMG activity Batch Management - Batch
Determination and assigned in Customizing for Repetitive Manufacturing in the IMG activity
Materials Staging). Its function is to specify the sequence of the strategy types. In turn, the system
then tries to determine strategy records for these strategy types within batch determination.
© SAP AG
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
Prerequisites for the stock determination:
 The stock determination strategy must be defined using the Stock Determination step in
Customizing for Inventory Management. This strategy is comprised of the stock determination
group and the stock determination rule with extended parameters. The stock determination strategy
contains the concrete control parameters for the stock determination. It is structured using header
data and item data: You enter stock types and storage locations into the item table in a priority
sequence.
 The stock determination rule must be assigned at plant level. You do this using the Define Control
Data for Pull List step in Customizing for Repetitive Manufacturing. The stock determination rule
assigns a stock determination strategy for the stock transfer of the pull list for each plant.
When processing materials requiring batch handling, this configuration path is also used to assign
the batch search procedure.
 You must assign the stock determination group in the component's material master record. The
stock determination group assigns a stock determination strategy to the material. Stock
determination can only be executed for these materials.
© SAP AG
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Storage Location and Supply Area Determination
Scenario: Stock transfer for component D
Question: To which storage location?
A
1. Priority
B
C
D
BOM
Issue storage location from
BOM item for component D
Strategy for storage location determination according to MRP
group in the material master record of material A
A
2. Priority
B
C
A
D
Material master
Material D:
Issue storage
location
Issue stor. loc. selection = 1
in MRP group for material A:
Issue stor. location from material
master record for component D
B
C
D
Production version
Material A:
Proposal issue
stor. loc.
Issue stor. loc. selection = 2
in MRP group for material A:
Proposed issue storage location
from production version for assembly A
 SAP AG 2004
 Use: The issue storage location must already have been determined for the pull list by MRP (because the
system does not take dependent requirements into account without an entry for a issue storage location): Here,
the system first searches for the issue storage location in the BOM item of the component (field Issue storage
location). If no storage location is maintained in the BOM item, the MRP group of the assembly determines
whether the issue storage location from the material master record of the component or from the production
version of the assembly is to be used (strategy for issue storage location selection). This strategy is defined
per MRP group in Customizing for Repetitive Manufacturing in work step Define Storage Location and Supply
Area Determination in BOM Explosion.
• Storage location = 1: The system adopts the issue storage location in the components' material master
record as the issue storage location. You can use this procedure when there is a predefined storage
location for each component in the plant.
• Storage location = 2: The system uses the proposed issue storage location in the production version of
the finished assembly or product as the issue storage location for all components. If a proposed issue
storage location has not been maintained, then the system adopts the assembly's receiving storage
location as the issue storage location for all components. You can specify the receiving storage location
via the Receiving storage location field in the assembly's production version or via the Issue storage
location field in the assembly's material master. If no entry is maintained, you can define the receiving
storage location at backflush. This will then be used as the issue storage location for the components. You
should use indicator 2 when all components are stored together in a storage location near the production
line where they are required.
• Storage location = 3: Initially as for indicator 1. If the system finds no storage location here, it proceeds
as described under indicator 2.
• Storage location = 4: As indicator 3 but with reversed sequence.
• If no MRP group has been maintained for the assembly/finished product, the system reads the entry in the
field Issue storage location in the material master of the component as the issue storage location for all
components.
© SAP AG
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
Use: You use a stock transfer reservation if you do not want to execute a direct stock transfer.
Stock transfer reservation differs from direct stock transfer in that you can only reserve the required
components using the pull list in the stock transfer reservation process. The actual stock transfer
posting takes place in a separate step.

Activities: You work according to the process "Pull list with direct transfer posting". When you save
the pull list, however, the system does not post the transfer directly but generates stock transfer
reservations first. At a later time, you can select and process these stock transfer reservations further
using a picking list.
You can generate a list of reservations in this way. You can use the batch and stock determination in
the picking list to determine the replenishment storage location for the required components. You
can use this data to transfer the components and post the goods movement in the picking list.

Prerequisites:
 The prerequisites are the same as those for "Pull list with direct transfer posting".
 You transfer the standard settings into the Global settings in the initial screen of the pull list and
also select the indicator Stock transfer reservations.
© SAP AG
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Pull List: Staging Types
Pull list
 Storage location level
(direct posting change,
stock transfer reservation)
 WM release order part
 WM pick part
Reqmts
Stock
Reqmts
Stock
Reqmts
 Event-driven KANBAN
Missing parts
Reqmts
Stock
Stock
Missing parts
Missing parts
Missing parts
 SAP AG 2004

Use: You use the staging type to choose how you stage components in Production with the pull list.
In the initial screen of the pull list, you can choose between four provision types:

Storage location level (direct stock transfer, stock transfer reservation): In direct stock transfer,
the system posts the stock transfer immediately when you save. With stock transfer reservations, the
system creates manual stock transfer reservations for the required components. The staging takes
place in a further step.

WM release order parts (generation of WM transfer requirements or transfer orders for WM
release order parts): The system generates transport requirements or a transfer order as a
replenishment element. With release order parts, the system groups the individual requirements of
a specific supply area and compares them with the available quantity (i.e., stock and replenishment
that has already been triggered) at that supply area. Components are therefore not staged referencing
a particular order.

WM pick parts (generation of WM transfer requirements or transfer orders for WM pick
parts): The system generates transport requirements or a transfer order as a replenishment element.
For pick parts, the system takes note of the quantity that has already been staged for each individual
requirement. If this quantity is smaller than the quantity required, a requirement-specific missing
parts quantity is identified. Component staging is therefore order-related. Replenishment is only
triggered for a concrete requirement.
This pick parts procedure in the pull list can only be used for repetitive manufacturing.

Event-driven KANBAN (generation of kanban replenishment elements): The system generates
kanbans with status "empty". This triggers the replenishment. All KANBAN functions are available.

In the pull list, you can set different units of measure as the staging unit of measure (Global Settings
in the initial screen),
© SAP AG
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Triggering Replenishment via WM
(for Release Order Parts)
Storage bin 1: Mat.A
(storage type 100)
Direct presentation of
missing parts situation
per storage bin
Storage bin 2:Mat.B
(storage type 100)
Issue supply area 1
Co
nt
ro
lc
irc
le
Transfer
requirement or
alternative
transfer order
Pull list
Reqmts
Stock
Missing
parts
Replenishment
storage location
WM-managed
(e.g. central
warehouse)
 SAP AG 2004

Use: Replenishment of components to production can also be triggered by Warehouse Management
(WM). You always use the WM process if your replenishment storage location comes under WM.

Activities: Transfer requirements (that is, replenishment elements for WM) can be generated directly
from the pull list. These will be converted at a later date into a transfer order by the people in charge
of the WM. If Immediate TO creation has been chosen in the initial screen of the pull list, the
system immediately generates transfer orders (assuming the user has appropriate authorization to
create transfer orders). A list of the replenishment elements can be printed, to be passed on to
warehouse personnel. Once the requirements have been staged, the goods movement is confirmed by
warehouse personnel.

With release order parts, the system groups the individual requirements of a specific storage bin on
the production line and compares them with the available quantity (i.e., stock and replenishment that
has already been triggered) at that supply area. Components are therefore not staged referencing a
particular order. Release order parts are used primarily for Repetitive Manufacturing, since, as a
rule, this is also not an order-specific process.

Prerequisites:
 A supply area must be maintained as issue supply area in the BOM or material master.
 The storage location to which the supply area is assigned is managed by WM.
 A WM control cycle must be maintained, with the material staging indicator 3 (release order part)
for the supply area.
 The WM release order parts provision type must be specified in the initial screen of the pull list.
You then access the release order part view directly.
© SAP AG
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
Use: Replenishment of components to production can also be triggered using event-driven
KANBAN. You use event-driven KANBAN if you want to make use of the advantages of the
KANBAN module (replenishment using containers) but still want an irregular consumption run. In
this case, you cannot use the classic KANBAN with a fixed number of kanbans (containers) for the
replenishment. In such cases, you can therefore generate an event-driven kanban with the status
"empty" from the pull list. This kanban is then deleted after one replenishment.

For event-driven KANBAN, there is no predefined number of containers or container quantity.
Replenishment is triggered only when a specified event occurs. You can trigger an event either
manually from the KANBAN menu or using the pull list. Materials are therefore not constantly
staged and replenished by the system, but only upon explicit request. The system creates a container
for every material quantity requested; the container is deleted once replenishment has been carried
out.
Note: The term "event-driven KANBAN" is somewhat misleading, since in classic KANBAN the
material flow is automatically controlled by a constant flow of a fixed number of containers and
container quantities. In the case in question, the system requests the replenishment using a triggering
operation.

Prerequisites:
 A supply area must be maintained as issue supply area in the BOM or material master.
 A control cycle for event-driven KANBAN (the pull list supports only event-driven KANBAN)
must be maintained.
 The event-driven KANBAN staging type must be specified in the initial screen of the pull list. You
then access the event-driven KANBAN view directly.
© SAP AG
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Pull List: Additional Functions
 Dialog control
 Saving the total log
 Various units of measure for staging
 Displaying the available stock in the pull list
 Customer exit SAPLRMPU for adjusting print data,
converting units of measure, rounding replenishment
proposals.
 SAP AG 2004

Dialog control: You have the option of carrying out individual steps in material staging
automatically. The staging of materials is divided into four or five steps, all of which you can either
carry out online or automatically. In the Global Settings in the pull list you can determine which
steps are to be carried out automatically. You can thus also schedule the material staging in the
background.

Total log: You have the option of saving the total log, which contains all messages for the current
sitting. You enter this in the Global Settings in the pull list (on the tab page Dialog control). You can
view the total logs saved, via Pull List -> Log. The system can save a maximum of the last three
logs of a user.

Initial screen: The selection criteria can be saved as variants.

Units of measure: You can determine various units of measure as a staging unit (entry unit, issue unit
from the material master view Plant date/storage, WM unit, WM unit control, proportion unit) and
in this way represent the missing parts situation. You determine the unit of measure in the Global
Settings.

Displaying the available stock: In the pull list you can view the available stock for a material, in
detail.

Customer exit SAPLRMPU for adjusting print data, converting units of measure, rounding
replenishment proposals.
© SAP AG
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Material Staging: Summary
 KANBAN, storage location MRP (consumption-based)
and pull list (demand-based) as an alternate concept
of material requirements planning
 Direct stock transfer, replenishment via WM,
and replenishment via event-driven KANBAN
using the pull list
 SAP AG 2004

Note: A customer exit (enhancement SAPLRMPU) is available in the pull list. This consists of the
following function modules: EXIT_SAPLRMPU_001: ALV print of requirements totals,
EXIT_SAPLRMPU_002: ALV print of requirements details, EXIT_SAPLRMPU_003: ALV print of
replenishment elements, EXIT_SAPLRMPU_004: ALV print of comment block in list header. By
using these user exits, you can adapt the print data to your requirements before printing. You can
also print the adapted data yourself or have the system do this.
EXIT_SAPLRMPU_005: Conversion of the base unit of measure into the alternative quantity,
EXIT_SAPLRMPU_006: Conversion of the alternative unit of measure into the base quantity,
EXIT_SAPLRMPU_007: Rounding of replenishment proposals, EXIT_SAPLRMPU_008: Reduce
proportions of requirements: The use of these is described in detail in the documentation for the
individual modules. There are also example codings for some components that are very useful.
© SAP AG
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Exercises
Unit:
Material Staging
Topic:
Stock Transfer from Storage Location
Level and Using Warehouse Management
At the conclusion of this unit, you will be able to
• Use the pull list to stage intra-enterprise components on your
production line
The personal computer is manufactured in your plant 1200 in
Dresden. There are different production lines for the final
assembly and for manufacturing the assemblies.
As foreman, you are responsible for implementing the planning
specifications provided by the production planner. As cost center
manager, you monitor production and are responsible for material
staging at the production lines.
You now have the task of controlling component staging at the
production lines. On the one hand, components from the material
storage location must be staged on the assembly production lines.
On the other hand, those components that are not produced on the
assembly production lines and required for the final assembly
must be staged directly from the material warehouse.
7-1
In the following example, you use the pull list to transfer stock from the central
warehouse to the production line.
Execute component staging for the assembly production line.
7-1-1 To do this, access the pull list for your T-L3## production line in plant
1200. You want the material staging for this production line to be executed
for all requirements that exist for the period up to Monday of next week.
Most components are staged from a central warehouse that is not managed
using the Warehouse Management module. You therefore choose the
Storage location level staging type.
Some steps should be carried out automatically by the system during
material staging. Choose Global Settings:
In the dialog box that appears, select the Dialog control tab page.
Here, make the following settings for the dialog steps:
© SAP AG
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Field name or data type
Values
Create replenishment proposals
Automatic
Execute batch/stock
determination
Automatic
Stage replenishment proposals
Automatic
Post replenishment elements
Online
Print replenishment elements
Online
Confirm with Enter and execute the report.
7-1-2 For which materials have planned requirements caused missing parts up to
Monday of next week?
______________________________________________________
7-1-3 For which storage locations are there missing parts? At which storage
location has the system found an available quantity for component T-T6##?
______________________________________________________
7-1-4 Now carry out the actual transfer posting of component T-T6## from
material storage location 0001 to production storage location PL03 on the
production line.
When you save, the R/3 System makes the transfer posting for the
material.
The components must then be physically transported from the central
warehouse to the production storage location.
7-1-5 Check the stock transfer posting using the message log for the pull list
(separate transaction).
© SAP AG
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7-2
Optional exercise (time permitting)
In the following exercise, you use the pull list to transfer components from a central
warehouse that is managed by the Warehouse Management (WM) system.
Execute component staging for the assembly production line.
7-2-1 To do this, access the pull list for your T-L3## production line in plant
1200. The material staging for this production line is to be executed for all
requirements that exist for the period up to Tuesday of next week.
Select the components that are transferred from a central warehouse that is
managed using the Warehouse Management module. Choose the WM
release order parts staging type.
The system should automatically execute some steps in the pull list. Choose
Global Settings:
In the dialog box that appears, select the Dialog control tab page.
Here, make the following settings for the dialog steps:
Field name or data type
Values
Create replenishment proposals
Automatic
Stage replenishment proposals
Online
Post replenishment elements
Online
Print replenishment elements
Online
Confirm with Enter and execute the report.
7-2-2 For which materials have planned requirements caused missing parts up to
Tuesday of next week?
______________________________________________________
7-2-3 For which storage bin and production supply area are there missing parts?
To which storage location does the storage bin belong?
______________________________________________________
7-2-4 Create a transfer requirement within the warehouse 0088 (WM warehouse)
for the T-TE## component.
To do this, select the replenishment element for material T-TE## in the
Replenishment elements table below and choose Stage and then Save.
7-2-5 From the Warehouse Management menu, display the transfer requirement
generated above:
Logistics  Logistics Execution  Internal Whse Processes  Transfer
Requirement  Display  For Material
© SAP AG
Field name or data type
Values
Warehouse number
001
Material
T-TE##
Plant
1200
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Solutions
Unit:
Material Staging
Topic:
Stock Transfer from Storage Location Level and
Using Warehouse Management
7-1
7-1-1 Menu path:
Logistics  Production  Repetitive Manufacturing
Material Staging  Pull List - Trigger Replenishment
Staging Type: Stor. loc. level
Plant: 1200
On the Planned orders tab page, choose:
Field name or data type
Values
Selection period for
requirements
Monday of next week
Production line
T-L3##
7-1-2 The planned requirements have caused missing parts up to Monday of next
week for material T-T6##.
7-1-3 There are missing parts for storage location PL03. The system found an
available quantity for component T-T6## at storage location 0001 (material
warehouse).
7-1-4 - No solution necessary 7-1-5 Menu path:
Logistics  Production  Repetitive Manufacturing
Material Staging  Log
Choose Execute.
Double-click on your document.
© SAP AG
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7-2
7-2-1 Menu path:
Logistics  Production  Repetitive Manufacturing
Material Staging  Pull List - Trigger Replenishment
Staging type: WM rel.ord. part
Plant: 1200
On the Planned orders tab page, choose:
Field name or data type
Values
Selection period for
requirements
Tuesday of next week
Production line
T-L3##
7-2-2 The unplanned requirements have caused missing parts up to Tuesday of
next week for material T-TE##.
7-2-3 There are missing parts for storage bin PROD-L3WM and supply area
PVB_L3WM. These belong to the 0088 storage location (Warehouse
Management warehouse). You can see this in the Additional Data field.
7-2-4 - No solution necessary –
7-2-5 - No solution necessary -
© SAP AG
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Backflush
Contents:
 Backflushing Yield
 Scrap
 Backlogs from Backflushing
 Reversals
 Reporting Point Backflush
 Period-End Closing
 SAP AG 2004
© SAP AG
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Backflush: Course Objectives
At the conclusion of this unit, you will be able to:
 Carry out backflushing in repetitive manufacturing
 Post scrap
 Process backlogs
 Reverse incorrect postings
 Carry out a reporting point backflush
 Describe the process of cost controlling in the
product cost collector
 SAP AG 2004
© SAP AG
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© SAP AG
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7-3
Backflush: Business Scenario
 In your plant 1200, you produced the PC on the final
assembly production line and the PC motherboard on
the assembly production line T-L3##.
 Now the quantity produced must be backflushed in
the R/3 System.
 SAP AG 2004
© SAP AG
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
John is responsible for planned orders in his area, material staging, KANBAN, backflushing,
operational method sheet, plant management (extra single role), cost center management (extra
single role), personnel management (extra single role), and quality management (extra single role).

He requires authorization for the following master data (display and change, if necessary):
Production versions, line design (work centers, rate routings, line hierarchy, line balancing,
operational method sheet), material master, material BOMs, production resources and tools, serial
number maintenance, documents (drawings and so on), control cycles (kanban and WM), supply
areas, delivery schedule, vendor, customer.

He requires authorization for the following planning transactions: Planning table, sequencing,
collective availability check, stock/requirements list, pegged requirements, stock overview,
production list.

He requires authorization for the following material staging transactions: Triggering material
staging, displaying material staging, stock transfer of components, picking, displaying logs.

He requires authorization for the following backflushing transactions: Collective backflush, final
backflush, reporting point backflush, KANBAN backflush, posting with correction
(activities/components), scrap backflush, separate backflush, reversal, postprocessing.

He also requires authorization for evaluations (production, inventory management and
controlling).
© SAP AG
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7-5

Ilja is responsible for creating backflushes (reporting point backflush, final backflush), kanban signal
(bar code, manual), reversing backflushes (exception), and goods movements.

He requires display authorization for the following master data: Documents, operational method
sheets, production resources and tools.

He requires display authorization for the following planning transactions: Display production list
(order sequence)

He requires display authorization for the following material staging transactions: Material staging
(displaying situation)
© SAP AG
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General Backflushing Functions in Repetitive
Manufacturing: Course Objectives
At the conclusion of this topic, you will be able to:
 Use the general backflush functions in
repetitive manufacturing
 SAP AG 2004
© SAP AG
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Backflush: Overview
 Backflushing production
 Documentation of the production
process
 Regular creation of the completed
production quantities
Backflush
 No order-based backflush
(Exception: Make-to-order
production). Quantity and periodbased backflushing methods used
instead (more simple, reduced
posting effort).
 Personalization of the backflush
transaction
 SAP AG 2004

In Repetitive Manufacturing, progress in the production process is backflushed.

Unlike Discrete Manufacturing, backflushing in Repetitive Manufacturing is not dependent on the
order. Instead, it is typically carried out at regular intervals for the respective finished production
quantities (quantity and period-based backflushing).

Quantity and period-based processing facilitates administration and reduces administration costs.

Personalization of the backflush transaction: You can configure the initial backflushing screen,
that is, you can define it according to your own requirements and preassign specific fields. You can
arrange the screens individually using transaction variants: You can hide fields and tab pages that
you do not require, and take functions out of the menu. Some transaction variants have already been
delivered preconfigured and can be individually adjusted by the customer. If possible, the transaction
variants are set by system administration for the relevant users (transaction SHD0). For further
information see the SAP online documentation.
© SAP AG
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Backflush
Receiving storage location
Material A
Goods receipt
Production line
Goods issue
Issue storage location 1
Material B, C
Goods issue
Issue storage location 2
Material D
 SAP AG 2004

The simplest form of backflushing in Repetitive Manufacturing is the final backflush. This means
that the finished materials are backflushed at the end of the production process.

In the Repetitive Manufacturing final backflush, the system posts the goods receipt of the assembly
(or the finished product) to the receiving storage location and backflushes the component withdrawal
from the issue storage location.

The receiving storage location is maintained in the production version of the assembly or the finished
product (in the To location field) or alternatively in the material master record of the assembly of the
finished product (Issue storage location field). If the storage location was maintained in both fields,
the system gives the storage location in the production version first priority.

You can maintain the issue storage location for the backflush in the BOM, the material master record
and in the production version (Issue storage location or Proposed issue storage location fields).

The control parameters for final backflushing are maintained in the repetitive manufacturing profile.
If a repetitive manufacturing profile is maintained for the assembly, which supports the backflush,
then all components of the assembly (up to bulk material) are backflushed. One control per
component is not possible. The Backflushing indicators in the routing, material master, and work
center from Discrete Manufacturing are not relevant for Repetitive Manufacturing.

In the backflush transaction you can change the stock type to be used for posting the goods receipt
using the Details button: unrestricted-use stock (standard setting), blocked stock, or stock in quality
inspection.
© SAP AG
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
In the final backflush, the system explodes the BOM in one of the following ways:
 The system explodes the current BOM according to the posting date (the alternative BOM and
the BOM usage from the production version).
 If you enter a revision level, the BOM is exploded at the revision level entered.
 If you enter a planned order, the component list of this planned order is exploded.

If both a planned order number and a revision level are entered for a BOM, then the planned order
takes precedence in the final backflush. In this case, therefore, the system only imports the planned
order component list.
© SAP AG
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Storage Location and Supply Area Determination
Scenario:
Backflushing assembly A,
goods receipt for component D
Question: From which storage
location?
A
1 Priority
B
C
D
BOM
Issue storage location from
BOM item for component D
Strategy for storage location determination according to MRP
group in the material master record of material A
A
2 Priority
B
C
A
D
Material master
Material D:
Issue storage
location
Issue stor. loc. selection = 1
in MRP group for material A:
Issue stor. location from material
master record for component D
B
C
D
Production version
Material A:
Proposal issue
stor. loc.
Issue stor. loc. selection = 2
in MRP group for material A:
Proposed issue storage location
from production version for assembly A
 SAP AG 2004
 Use: When backflushing, the component backflush is usually posted from the corresponding issue storage
locations. Here, the system first tries to post the components from the issue storage locations maintained in the
BOM item of the component (Issue storage location field). If no storage location is maintained in the BOM
item, the MRP group of the assembly determines whether the issue storage location from the material master
record of the component or from the production version of the assembly is to be used (strategy for issue
storage location selection). This strategy is defined per MRP group in Customizing for Repetitive
Manufacturing in work step Define Storage Location and Supply Area Determination in BOM Explosion.
• Storage location = 1: The system adopts the issue storage location in the components' material master
record as the issue storage location. You can use this procedure when there is a predefined storage
location for each component in the plant.
• Storage location = 2: The system uses the proposed issue storage location in the production version of
the finished assembly or product as the issue storage location for all components. If a proposed issue
storage location has not been maintained, then the system adopts the assembly's receiving storage
location as the issue storage location for all components. You can specify the receiving storage location
via the Receiving storage location field in the assembly's production version or via the Issue storage
location field in the assembly's material master. If no entry is maintained, you can define the receiving
storage location at backflush. This will then be used as the issue storage location for the components. You
should use indicator 2 when all components are stored together in a storage location near the production
line where they are required.
• Storage location = 3: Initially as for indicator 1. If the system finds no storage location here, it proceeds
as described under indicator 2.
• Storage location = 4: As indicator 3 but with reversed sequence.
• If no MRP group has been maintained for the assembly/finished product, the system reads the entry in the
field Issue storage location in the material master of the component as the withdrawal storage location for
all components.
© SAP AG
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Integrated Batch and Stock Determination
Storage location determination defines from
which storage location you backflush
BOM
GR
Unrestricteduse
consignment
stock
Vendor 1
A
Backflush
B
C
D
C
C
GI
Batch
P
Unrestricteduse
consignment
stock
Vendor 2
C
C
C
Storage
location 1
Unrestricteduse
P
C
P
C
 SAP AG 2004

Using stock determination (previously known as withdrawal sequence) enables you to control from
which stock the components should be withdrawn in the final backflush; for example, first from the
unrestricted-use stock and then from the consignment stock, or vice versa. If different consignment
stock is offered by different suppliers, you have the option of specifying that the supplier offering the
most competitive prices and who has sufficient available stock be the one chosen first. You can also
execute stock determination for pipeline withdrawals. In order to do this you must first maintain
purchase info records. This also applies for consignment stocks.

Note: The issue storage location for the component withdrawal is usually determined in storage
location determination (see previous slide) as requirements without any predetermined storage
location cannot be processed with the pull list, for example. Therefore, the stock determination
function in backflushing is often only used to determine special stocks. This means that stock
determination in backflushing only searches for the parameters not yet determined by storage
location determination.

Prerequisites:
 You need to define the stock determination strategy as a combination of a stock determination
rule, a stock determination group, and enhanced parameters in Customizing for Stock
Determination.
 You need to assign the stock determination rule in the material's repetitive manufacturing
profile.
 You need to assign the stock determination group in the material master record.

Batch determination: The system determines the strategy for controlling batch determination using
the batch search strategy and in accordance with the WM batch determination procedure. The
search strategy in repetitive manufacturing profile hereby controls the search strategy defined using
the movement type.
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Posting Production Activities During Backflush
Example:
Routing Material A
Oper- Work
ation center
10
Line3
for 30 pieces:
Prod.
rate
30 pc / hr
Target time: 1hr
Actual time:1.5 hr
Option 1:
Backflush:
Backflush qty: 30 pieces
no backflush
Planned production activities from
material cost estimate or
precalculation for product cost
collector
Additional
activity backflush:
Ref. qty: 0 pieces
Actual time: 0.5 hr
Actual production activity: Subsequent
difference posting
Option 2:
Backflush:
Backflush qty: 30 pieces
Actual time: 1.5 hr
Actual production activity: Post
during the backflush
 SAP AG 2004

Use: When backflushing, you can post the production activities to the product cost collector as well
as the material costs. A production activity is the effort required at a work center to carry out an
operation. Production activities can be posted as planned or as actual production activities:
• In the standard system, the planned production activities from the material cost estimate or
from the preliminary costing for the product cost collector are posted when backflushing.
• If the actual times differ from the planned times in the routing, you can also post the actual
times by overwriting the planned times (Actual times button under Actual data in the final
backflush). The actual times are then used as the basis for posting the actual production
activities. You can maintain one variance reason per operation. You can also add further
activities per operation (for example, teaching a new employee) which can be posted under a
separate activity type to another work center (and therefore to a different cost center).
• You can also post the actual times separately using the transaction activity backflush (should
you want to post differences, for example). To do this, enter "0" in the activity backflush in the
Ref. qty field. This means you can differentiate between a variance posting and a total activity
posting. The system proposes the corresponding operations for which you can make a variance
posting. Note: A separate activity backflush is not possible in make-to-order production.

Prerequisites:
• Material master: Repetitive manufacturing profile which allows you to record activities
(Activities field). Alternatively, you can activate the activity backflush by choosing Details in
the backflush screen.
• Production line: Enter a cost center and assign the default values to the activity types.
• Routing: Control key which allows backflushing and cost estimates.
• You have carried out either a material cost estimate with a price update or a preliminary costing
according to the setting in the repetitive manufacturing profile.
© SAP AG
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Controlling Integration
Product cost
collector
Material costs
Components
Debit
Production
activities
Debit
Overhead
Debit
$40
Balance sheet
account
Credit amount
equal to
valuation price for
assembly
$45
$10
$5
$55
- $45
$10
Variance
calculation
Settlement
of the
variance
Price
difference
account
for std price
materials
$10
 SAP AG 2004

The product cost collector collects the incurred actual costs.

In the final backflush, the system automatically posts both the components' material costs and the
production activities to the product cost collector. The product cost collector is therefore debited for
the components' material costs and the production activities. In the repetitive production profile you
can set whether the activities are to be backflushed according 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).

You do not determine overhead costs for each goods movement or activity confirmation, but
periodically via an overhead structure using the period-end closing function in Controlling. You then
post these to the production cost collector using a specific transaction in the Repetitive
Manufacturing menu.

It is possible that during production components other than the ones planned have been set and the
overheads have changed. This leads to variances emerging in the product cost collector. You must
then settle these variances so that the product cost collector can be completely credited. Upon
settling, the system forwards those costs that have not yet been debited by the cost collector. The
variance costs, meanwhile, are posted to the price difference account for a standard price valuated
material.
© SAP AG
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Reducing the Master Plan in Backflushing
Example: Material A
Backflush: 30 pieces
on production line 1
for material A
Case 1
line 1
line 2
Not yet assigned
Today Tomorrow Next day
0
0
10
10
10
5
Today
0
10
Tomorrow Next day
0
10
10
0
Case 2
Today Tomorrow Next day
0
0
10
0
10
0
Case 3
or
line 1
line 2
Not yet assigned
or
line 1
line 2
Not yet assigned
 SAP AG 2004
Reduction of
overproduction
line 1
line 2
Not yet assigned
Today Tomorrow Next day
10
5
10
10
10
5
Reduction period from repetitive
manufacturing profile (here: 1 day)

If open planned order quantities still exist in the past, these are reduced first.

In the backflush, the system reduces the planned orders for the material by the backflushed quantity.
In Customizing for Repetitive Manufacturing, in the repetitive manufacturing profile strategies you
can choose how to reduce planned orders. For possible overproduction, you can specify at what
point in the future the master production schedule should be adjusted (reduction period):
 Case 0: No reduction of the planned order.
 Case 1: Within the reduction period, the system reduces those planned orders that have been
assigned to the specified production version. Planned orders lying outside the reduction period are
not reduced, even if the backflushed quantity exceeds the planned order quantities within the
reduction period.
 Case 2: Within the reduction period, the system reduces those planned orders that have been
assigned to the production version. If the backflushed quantity should exceed the production
quantities within the reduction period, the system also reduces the planned orders that have not yet
been assigned to a production version. The planned orders are always reduced in the reduction
period.
 Case 3: The system reduces those planned orders that have been assigned to the specified
production version and also those that have not. As third priority, the system also reduces those
planned orders that have been assigned to other production versions of the material. The planned
orders are always reduced in the reduction period.
The repetitive production profile is shipped with case 1 as standard.
© SAP AG
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
The dependent requirements for components are typically reduced at the time of the assembly
backflush, by the component backflush. If the components are backflushed with the function
Separate Backflush, it is guaranteed that the dependent requirement is not reduced at the time of
backflush (as also the component stock on the production line is also not reduced at this time), but
only when the goods issue is posted for the components. If the components are not backflushed in
the usual manner (and not by the function Separate Bacfklush but manually via the backflush
deactivation in the repetitive manufacturing profile), the dependent requriements are already reduced
at the time of the backflush.

If the planned orders were created because of planned independent requirements, these planned
independent requirements are reduced with the goods issue from the storage location.
© SAP AG
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
When using Repetitive Manufacturing, the production process is greatly simplified; reflective of this
simplification, the following backflushing functions occur when performing a final backflush in the
standard system:
 Goods receipt of the assembly or finished product in the receiving storage location
 Backflushing the components from the issue storage location
 Posting the material costs to the product cost collector
 Posting the production activities to the product cost collector
 Adjusting the master production schedule (reduce the production quantities and capacity
requirements)
 Update the statistics of the Logistics Information System (LIS)/Business Information Warehouse
(BW)
 Creating a data entry document.

You can set options in the repetitive manufacturing profile to influence the above functions in
backflushing.

In addition, further functions are available in the backflushing transaction using the Details button:
You can activate the posting of lot size independent costs (setup costs or costs for lot-size dependent
material quantities which do not usually occur for every production quantity, but at the beginning of
a new production series, for example.) You can also activate the posting of component scrap (if you
do not select the indicator, the BOM explostion in the backflush does not take component scrap into
account). Planned order reduction is always carried out taking component scrap into account.)
© SAP AG
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Further Options for Backflushing (1)
 Collective backflush
 Backflush via plant data collection systems (PDC systems)
 Archiving the backflushing documents
 SAP AG 2004

Collective backflush: To facilitate backflushing, you have the option of backflushing data
collectively. You are therefore able to set various restrictions. For example, you can backflush
together several materials that are to be manufactured on the same production line.
 Backflushing using plant data collection systems (for example, stationary bar code scanner):
Various BAPIs (Business Application Program Interface) are available which you can use to record
the type and quantity of materials produced. These guarantee the functions on the initial screen of the
backflushing transaction MFBF: Backflushing for make-to-stock production, make-to-order
production, production by lots, reporting point backflush, activity backflush, component
consumption backflush, backflush reversal (only document-specific reversal, not non-documentbased reversal), however, no correction of actual quantities and actual activities when backflushing
(Posting with correction button) and no detailed settings (Detailed settings for backflush button).
These functions are grouped into four processes. A BAPI exists for each process: Backflush for nonorder-based Repetitive Manufacturing, backflush for order-based Repetitive Manufacturing,
backflush for production by lot-based Repetitive Manufacturing, reversing a backflush. The BAPIs
for the individual processes are defined by the newly created SAP Business Object BUS2127 (SAP
R/3 4.6B: BUS2127) Backflushing in Repetitive Manufacturing.
 Archiving the backflushing documents: You can archive the data in the backflushing documents
from Repetitive Manufacturing with the archiving object PP_BKFLUSH if you no longer require
immediate access to them in the system. Here, the system records the data to archive files and then
deletes the data in the system if the transaction was successful. If necessary, you can reload the
backflushing documents back into the R/3 System. The data of a backflush log is saved in various
different tables (see the SAP Online Documentation). You can also archive the documents for the
product cost collector with the archiving object CO_ORDER, after you have archived the
backflushing documents. The material documents from backflushing are archived in Repetitive
Manufacturing, but are not deleted. You can use the archiving object MM_MATBEL when archiving
the material documents to re-archive them or to delete them.
© SAP AG
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Further Options for Backflushing (2)
 Goods issue backflush:
Only goods issue, no production
activities (component
consumption for non-exact
BOMs, manual subsequent
backflushing)
BOM
A
B
C
D
?
 Activity backflush:
(Such as multiple activities)
 SAP AG 2004

You can use the goods issue backflush to post excess component consumption if this excess
component consumption has not already been posted when backflushing the assembly (using the
Post with correction button).
You can also use the function to repeat the backflush manually if you have defined in the repetitive
manufacturing profile that the components are not to be backflushed (without, however, using the
separated backflush where the goods issues are automatically posted subsequently).
Using this function only posts goods receipts and not production activities. Excess consumption as
quantity variation is posted with the goods issue movement type 261 and not with the scrap
movement type 551. A separate transaction is used to post scrap.
Activity: Choose the Component backflush pushbutton, Component scrap button, Propose
components according to BOM button, enter the material number of the assembly (not the
component) in the Material field. If you choose the function Process component list, the system uses
the quantity specifications to explode the current BOM for the assembly and in the following screen
displays all components. Here, you can enter the scrap quantities for each component as necessary
and you can delete the components for which no scrap exits. If you enter a reference quantity in the
Reference quantity field before choosing the Process component list function, the system
automatically calculates quantities for the components.
If you choose the No BOM explosion (manual component entry) pushbutton and then the Process
component list function, you have to enter every individual component manually for which scrap
may exist.
 Activity backflush: If, when a material is manufactured, more (or less) activities are used than
planned, and these activities were not posted at the time of backflushing, they can be subsequently
posted using the Activity backflush function. (Ref.qty. field for the assembly). Enter a negative
quantity. You can also use the function to subsequently post all the actual activities if you defined
that the backflush is to be posted without activities in the repetitive manufacturing profile. With this
function, the system only posts production activities and no goods issues. Note: A separate activity
backflush is not possible in make-to-order production.
© SAP AG
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Backflushing Scrap
Scrap backflush
 Assembly scrap:
GI for components and production activities
 Component scrap:
GI for components only
 Activity scrap:
Only production activities
 SAP AG 2004

Assembly scrap for posting scrap for an assembly/finished product: Using this function, the system
posts goods issues for components and it also posts the production activities. The product cost
collector is debited with the material costs for the components and the production activities. In
Controlling, the assembly scrap backflush is updated internally for further evaluations.
Activity: Choose the Assembly backflush pushbutton, Scrap button.

Component scrap: A specific movement type (551) is provided for the component scrap backflush,
so that you can also define a separate cost element in Controlling. You can assign the scrap
separately in Controlling. Using this function only posts goods receipts and not production activities.
Activity: Choose the Component backflush pushbutton, Component scrap button, Propose
components according to BOM button, enter the material number of the assembly (not the
component) in the Material field. If you choose the function Process component list, the system uses
the quantity specifications to explode the current BOM for the assembly and in the following screen
displays all components. Here, you can enter the scrap quantities for each component as necessary
and you can you can delete the components for which no scrap exits. If you enter a reference
quantity in the Reference quantity field before choosing the Process component list function, the
system automatically calculates quantities for the components.
If you choose the No BOM explosion (manual component entry) pushbutton and then the Process
component list function, you have to enter every individual component manually for which scrap
may exist.

Activity scrap. With this function, the system only posts production activities and no goods issues.
If, for example, activities have arisen due to incorrect usage of a defective component, you can post
these here. The process is the same as for activity backflush.
Activity: Choose Activity backflush button, then Activity scrap button.
© SAP AG
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
Errors may occur when saving the backflush: For example, the stock level in the R/3 system at the
time of the withdrawal posting may not cover the required quantity completely or there may be some
error in the master data if, for example, the system cannot determine the storage location.
Backflushing can therefore only be carried out successfully when the stock level in the system
completely covers the requirements quantity of a component.
If this is not the case, you can either create a backlog for the complete requirements quantity or you
can work using negative stocks (the use of backlogs is usually the preferred method in Repetitive
Manufacturing).

The system can react in various ways to errors when posting the backflush (Mandatory online
correction indicator, Optional online correction indicator in the repetitive manufacturing profile).
•No online correction. In this case, the system creates postprocessing records or negative stocks
if errors occur.
•You must correct the component quantity or the storage location online. The system only
allows the posting to be completed when all errors have been corrected.
•A correction is optional. In this case, you are asked whether you want to correct the
withdrawal error (then the system proceeds as under point 2) or not (then the system proceeds
as in point 1). If you choose the online correction, the system branches to the component
overview. Here, you can correct the error, that is, you can change, add, or delete components.
© SAP AG
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Backlogs from Backflushing
Stock in the R/3 system
for component D
50
Initial situation
Component
postprocessing list
D: 100
Backflush for
component D 100 pc
50
 SAP AG 2004

Use: If the complete requirements quantity is not available for a component when backflushing, you
can instruct the system to create a backlog for the complete requirements quantity.

Two options are available for creating backlogs (indicators Create cumulated postprocessing records
and Create individual postprocessing records in the repetitive manufacturing profile).

Creating cumulated backlogs from backflushing: In this case, all backlogs which occur for a
material/production version are saved in a collective document. Using this process, you positively
influence system performance. It does, however, have the disadvantage that you can then only
process the postprocessing record when the entire cumulated quantity has been posted to the
warehouse in the system. Another disadvantage exists when reversing. In this process, the system
cannot reproduce the link to the original backflushing document and the individual missing quantity
per backflush. Therefore, when reversing, the postprocessing records are not updated. Another
disadvantage is that during postprocessing, the system posts on the posting date and not on the date
of the backlog.

Creating backlogs as well as individual postprocessing records: In this process, the system creates
a collective document and another individual document per incorrect withdrawal posting. Every
individual document contains the date of the backflush. You can only postprocess a postprocessing
record on the basis of this individual document if you can post the complete quantity of the
individual record. Another advantage of this process is when reversing: When reversing a backflush,
the system can determine the corresponding individual backlog document and delete it. This avoids
duplicate postings. At the same time, the backlog quantity in the collective document is adjusted.
However, this process is more performance intensive than the process without any individual
records.
© SAP AG
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Postprocessing Backlogs
D: 100
Goods receipt component
D - 120 pieces
170
D: 0
70
Postprocessing the backlog list
 Postprocess individually (MF45)
 Collective postprocessing (MF46)
 Postprocessing list (MF47)
 Individual component postprocessing (COGI) for
repetitive manufacturing and production orders
 SAP AG 2004

The following functions are available for postprocessing backlogs from backflushing:
 You can postprocess backlogs individually (per component) (transaction MF45): As opposed to
individual component processing (transaction COGI) here, you process totalled postprocessing
records. This means if several errors occur for one particular component, these are grouped into a
postprocessing record.
 Postprocessing backlogs collectively (transaction MF46):
 Processing backlogs using a postprocessing list (transaction MF47): To postprocess backlogs
from backflushing, you can use this function to create a list of components that have to be
postprocessed.
 Individual component postprocessing (transaction COGI): You have the option of postprocessing
incorrect backflushes in repetitive manufacturing using the same interface as in production orders.
This means you can use the same transaction to process components you use in repetitive
manufacturing and in production-order-based manufacturing. The system also displays the posting
error when postprocessing.
This type of postprocessing, however, is only possible for individual postprocessing records. In
this case, the system has to create a separate postprocessing record for every error which occurs
when backflushing components as the reference of the backflush to the postprocessing record must
be maintained.

You can trigger automatic postprocessing with a batch job by using report RMSERI13. To do this,
in the step Backflushing -> Background Jobs -> Define Background Job for Backflushing Processes,
schedule the background job for backlog postprocessing.
© SAP AG
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Negative Stocks
Stock in the R/3 system for component D
Initial situation
50
Backflush for
component D: 100 pc
-50
Goods receipt component
D for 120 pc
70
Postprocessing the backlog list
none
 SAP AG 2004

Use: If you want to reduce the effort involved in processing reprocessing records, in the event of a
stock shortage you can set the system to post negative stocks instead.

Prerequisites:
 Customizing for Inventory Management in the Goods Issue/Transfer Postings step: Negative
stocks are permitted.
 Material master (View: Plant Stock/Storage Location): set the Negative stocks per material
indicator.
© SAP AG
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
You have the option of reversing backflush to correct posting errors. Reversing deletes the total
backflushing documents (which form the basis for all manner of individual documents). The same
applies for the following data:
 The goods receipt and all associated material documents are reversed through the creation of a
new goods movement document. The associated total backflushing document is also flagged as
reversed.
 The goods issues for the components are reversed - that is, the component quantities are posted
back.
 The activities are reversed.
 Backlogs from backflushing: If, in the repetitive manufacturing profile, you set for an individual
document to be created per postprocessing record generated, then the system deletes the dependent
individual documents and adjusts the quantity in the cumulated reprocessing record document.

According to the setting in the repetitive manufacturing profile, the reversed quantity is accounted
for in the following way (planned order procedure):
 The system does not automatically generate a planned order and so the planner must personally
check the situation.
 The system creates a planned order in the amount of the reversed quantity for the current day.
 Alternatively, the system triggers a single-item planning run (MRP) asynchronously, which, in
turn, creates a planned order (adjusted to the changed planning situation).

As capacity planning is usually already completed when reversing, no capacity requirements are
recorded for the newly created planned order in the delivery system after the reversal. If, however,
you want to create capacity requirements for the new planned order when reversing, proceed as
described in the OSS Note 162961.
© SAP AG
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
In some areas, for example the chemical industry, it sometimes makes sense to backflush the
required quantities without first knowing the precise quantities. The system's sophisticated
measuring devices only calculate the actual quantity that was used is once production is complete.
You then need to report the required quantities after the event.

In order to do this, once individual components have been adjusted you can carry out a partial
reversal. To do this, you must choose the function Reversal not based on document in the initial
screen for backflushing.

You have the full range of backflushing functions at your disposal, albeit with reversed postings (for
example, the adjustment of the individual components).
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
Use: If you have high volumes to backflush, you can enhance system performance by separating the
performance-intensive processes Posting Goods Issue and/or Posting Production Activities from the
backflush.
• If you have separated the backflushing and posting production activities processes, the system
only posts goods receipts and reduces the capacity at the backflush.
• Goods issue and production activity postings are noted in a worklist for each final backflush.
This worklist is then processed later by means of a background job (separation of the
backflushing processes). Here, the worklist can be distributed over several servers (parallel
processing).
• The separated backflush is also possible when working with the reporting point backflush
(also in combination with aggregation: Then the aggregation is carried out per day, cost
collector, and reporting point. Therefore, if a component is assembled at two reporting points A
and B, the system posts two separate backflushes for reporting point A and B).

Prerequisites:
• In the process control profile (defined in Customizing for Repetitive Manufacturing and
assigned in the repetitive manufacturing profile) you set the time and method (online, as an
update task or in the background) for the subsequent backflushing of goods issues and/or
production activities, and define whether they should be aggregated.
• If you want to use background processing, you must also enter the background job for separated
backflushing (transaction (RMSERI70) in the step Backflush -> Background Jobs -> Define
Background Job for Backflushing Processes, schedule the background job for decoupled
backflushing (RMSERI70).
• In the step Define Times/Parallel Processing for Confirmation Processes, you control on which
servers/work processes the backflushing processes are carried out.
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
Use: When backflushing large amounts of data, you can also aggregate the backflush and/or the
production activity postings when separating the backflushing processes to improve performance. To
do this, proceed as follows:

Aggregation of goods issue posting:
• In make-to-stock repetitive manufacturing, the goods receipt quantities (usually without
reference to the planned order) are aggregated according to the selection criteria of the
collective backflush.
• When subsequently executing the backflushing process, the BOM is exploded per material for
the aggregated quantity.
• The goods issues are posted. All identical components are aggregated for posting.
• Dependent requirements for the components are reduced.

Aggregation of production activities:
• In make-to-stock repetitive manufacturing, the system aggregates the goods receipt quantities.
Production activities are calculated in proportion to this total quantity. The routing provides the
basis for this calculation.

Prerequisite: In the process control profile (definition in Customizing for Repetitive
Manufacturing in workstep Backflush / assignment in the repetitive manufacturing profile), you set
that the backflush and/or the production activitiy posting is to be aggregated.

The aggregation is carried out when posting the backflush/production activities. The reference of the
components to the assembly is lost during aggregation. After the aggregation, therefore, you have to
carry out any necessary reversal postings using the non-document-based reversal (and not the
document-specific reversal).
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Scenario: Mandatory Reporting Point Backflush
Production line 1
Work
center 1-1
Work
center 1-2
Work
center 1-3
Receiving storage location
Work
center 1-4
Goods receipt
Goods issues
Issue storage location
Issue storage location
Scenario: Long production line (greater lead time) - goods issue of the first
component on work center 1-1 should be posted on time, you should not wait until
the backflush at the end of the production line.
 SAP AG 2004

Usually at the final backflush, all components are backflushed that were installed along the
production line. If there are greater lead times, the goods issues of the components in the system may
be posted considerably later, after the actual physical withdrawal.

In this case it is a good idea to use reporting point backflushes to make the posting nearer the actual
component backflush, after the work operations have been completed.
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
Reporting point backflushing enables you to withdraw components near to the time of the
operation, even when dealing with large lead times, and to calculate the work in process. Here, you
do not confirm the quantities at the end of the production line (final backflush) but you enter the
quantities produced directly after important operations (reporting points). Reporting points are
defined in the routing.

The reporting point backflush in Repetitive Manufacturing is similar to the milestone backflush in
Discrete Manufacturing (production orders).

Backflushing reporting points causes all components assigned to the backflushed reporting point
operations and the preceding operations (up until the last reporting point) to be backflushed as well.
Moreover, the system posts the production activities for the reporting point operation and the
preceding operations (up until the last reporting point). For yields, the system reduces the
components' dependent requirements of the oldest planned order (dependent requirements are
adjusted according to plan). In the repetitive manufacturing profile, you can set the system to post
the goods receipt automatically upon the last reporting point being backflushed. The master
production schedule and therefore the capacity requirements are not reduced until the goods are
issued. The system also updates information, for example, in the Logistics Information System.

In the mandatory reporting point backflush, you must carry out a reporting point backflush at every
reporting point (otherwise, the system issues a warning that the backflush quantity at the missed
reporting point is less: In this case, you can set that the previous reporting points are to be
backflushed subsequently - you do this via the Details button on the initial screen for backflushing
(Posting previous reporting points indicator). This function subsequently posts the missed reporting
point quantities).

You can only execute reporting point backflushes for the main sequence of a routing.
© SAP AG
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 When each reporting point is backflushed, the backflushed quantities are cumulated in the run schedule header
per material. The quantities backflushed at each reporting point are only reduced on backflush at the last
reporting point (if the automatic goods receipt occurs here) or on final backflush. Reporting point backflushing
enables you to display "work in process" (WIP).
 Prerequisites for reporting point procedure:
 Material master: Assign the repetitive manufacturing profile which allows optional reporting points (in
repetitive manufacturing profile, Reporting point backflush indicator and the Optional button). In addition,
the repetitive manufacturing profile should support the activity backflush in accordance with the preliminary
costing (version-specific costing). Reason: If the routing is changed between two reporting point backflushes
(for example, available reporting point is deleted, new reporting point is added), then the internal reporting
point structures in the system are adjusted only by a preliminary costing with the product cost collector. If
the routing has changed after the last preliminary costing was created, then a warning message is issued at
the backflush and a new preliminary costing is created from the backflush. Either new preliminary costings
can either by created manually from the product cost collector or using a transaction in the repetitive
manufacturing menu. This ensures that, when backflushing, the production activities are posted on the basis
of the current routing.
 Routing: The routing must contain more than one operation: You are required to select a control key for the
reporting point operation which contains indicator 1 (milestone backflush) in the Backflush field.
In addition, you need to assign the components in the routing to the individual operations (Note: If you work
with the final backflush only, and not with the reporting point backflush, you do not have to carry out a
component assignment in the routing). Unassigned components are immediately deemed to belong to the
first reporting point.
You must enter the routing in the material's production version. To set up the internal reporting point
structure, the system first searches for the routing that is entered in the area of detailed planning in the
production version; if no entry has been maintained there, then the system copies the routing from the area
of rate-based planning.
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Mandatory Reporting Point Backflush:
Backflushing Assembly Scrap
Assembly scrap at reporting point:
 Goods issue for components and production
activities at reporting point
 SAP AG 2004

In the mandatory reporting point backflush, you have the option of backflushing assembly scrap.
Here, the system posts production activities as well as the goods issues of the components at the
reporting point and the previous operations (up to the last reporting point). To do this, choose:
Assembly backflush button, Reporting point backflush indicator, enter the reporting point in
Reporting point field, Scrap at reporting point button, enter the quantity in the Scrap quantity field.
The function Scrap up to reporting point is only relevant for the optional reporting point backflush.

Note for transaction Reset Reporting Points (RP) in the backflush menu of Repetitive
Manufacturing: Here, all quantities on the line are posted to assembly scrap. After executing the
transaction, no more quantities lie on the production line, work in process (WIP) was posted to scrap
(application: In the test system for testing purposes, in the productive system only if you really want
to post all the quantities currently on the production line to scrap).

General note on the reporting point backflush: After a reporting point backflush, the following
activities are carried out by the system: The goods issues for the components are posted, the system
determines the oldest planned orders are reduces the corresponding dependent requirements. If a
planned order for which dependent requirements have already been reduced is moved or deleted in
between backflushes, or if a new planned order is created as a result of a backflush reversal, the
dependent requirements are not automatically adjusted. The adjustment is not carried out until the
next backflush. To adjust the dependent requirements before the next backflush, you can plan a
background job for program RMSERI35 in this step. This background job is especially useful if a
lengthy period of time exists between backflushes and the planning is often changed between
backflushes.
© SAP AG
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Mandatory Reporting Point Backflush:
Backflushing Component Scrap
Assembly scrap at reporting point:
 Only the goods issue for components at the reporting
point (no production activities) or
 The goods issue for components at the reporting
point plus the posting of production activities
 SAP AG 2004

In the reporting point backflush, you can post the component scrap at the reporting point (if a
component was damaged before assembly). Only the goods issues for the components at the
reporting point and the preceding operations (up until the last reporting point) are posted, and not the
production activities.
To do this, choose: Component backflush button, indicator Reporting point backflush, enter the
reporting point in Reporting point field, Scrap button (if you choose Excess component consumption
instead of Scrap, the posting is made with a different movement type: 261 instead of 551), Propose
components according to BOM button, Components at reporting point button, enter the material
number of the assembly (not the components) in the Material field. If you choose the function
Process component list, the system uses the quantity specifications to explode the current BOM for
the assembly and in the following screen displays all components. Here, you can enter the scrap
quantities for each component as necessary and you can you can delete the components for which no
scrap exits. If you enter a reference quantity in the Reference quantity field before choosing the
Process component list function, the system automatically calculates quantities for the components.
If you choose the No BOM explosion (manual component entry) pushbutton and then the Process
component list function, you have to enter every individual component manually for which scrap
may exist.
Using the selection button Components after the last reporting point, you can post the components
that are assigned to the operation after the last reporting point in the routing.

If a component is damaged during assembly and production activities exist for these components,
you can post the component scrap and production activities in one transaction. To do this, choose:
Assembly backflush selection button, Reporting point backflush indicator, Scrap button, Component
scrap at reporting point selection button.
© SAP AG
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
Use: The optional reporting point backflush is particularly useful if you usually only backflush
at the end of the production process (final backflush), however, you want to post any scrap
directly at the operation or if, at the end of the period, you want to post the yield on the production
line to determine work in process.

You create the optional reporting point backflush using the same function as with the mandatory
reporting point backflush. As opposed to the mandatory reporting point backflush however, you do
not have to backflush at every reporting point.

For the optional backflush of assembly scrap at the operation, choose the pushbutton Assembly
scrap, indicator Reporting point backflush and the Scrap key in the REM backflushing transaction.
In the Scrap field, enter the quantity and choose Scrap up to reporting point. The system then posts
the backflush of those components that are assigned to the backflushed reporting point operation and
all preceding operations (in contrast to the mandatory reporting point backflush, the system also
backflushes components that are assigned to the preceding reporting point). In addition, the
production activities for both the reporting point operation and all preceding operations are posted.

To execute the optional backflush for yields at the operation, choose the pushbutton Assembly
backflush, the indicator Reporting point backflush and the Yield key. In the Details function, choose
the indicator Posting previous reporting points subsequently as in an optional yield reporting point
backflush the yield for the previous reporting points is not posted. Note: Before you return to a final
backflush after the optional yield backflush, you should repost the reporting point quantities by
manually posting the subsequent reporting points or by using the final backflush with function
Subsequently post previous reporting points.
© SAP AG
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
Prerequisites:
• Material master: Assign the repetitive manufacturing profile which allows optional reporting
points (in repetitive manufacturing profile, indicator Reporting point backflush along with the
pushbutton optional).
• All other prerequisites correspond to the prerequisites for the mandatory reporting point
backflush.
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Period-End Closing: Product Cost Collector
1. Process cost allocation
Product cost
collector
2. Recalculation of act. prices
3. Surcharges
4. Work in process
5. Variance costing
6. Settlement
 SAP AG 2004

In the CO period-end closing for the product cost collector, you can:
1. Carry out the process cost allocation
2. Revaluate the activities for the actual activity type with which the cost objects were debited.
3. Execute the overhead calculation.
4. Determine work in process.
5. Cost the variance.
6. Execute settlement.
In period-end closing settlements, the difference between credits and debits in the product cost
collector is posted to a price difference account.

The period end closing and details of cost object controlling are dealt with in course AC510
(cost object controlling for products).
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Special Backflushing Functions for MTO Repetitive
Manufacturing: Course Objectives
At the conclusion of this topic, you will be able to:
 Use the special backflushing functions for
make-to-order repetitive manufacturing.
 SAP AG 2004
© SAP AG
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Special Backflushing Functions for MTO Repetitive
Manufacturing
 Action control
 Backflush for make-to-order repetitive
manufacturing
 Special aggregation logic for separated backflush
 Valuation strategy for valuation of MTO stock
 No reporting point backflush
 No separate activity backflush
 SAP AG 2004

In make-to-order repetitive manufacturing, the reporting point backflush is not supported.

In make-to-order repetitive manufacturing, the separated activity backflush is not supported.

All other key points are covered in the following material.
© SAP AG
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
The function "Actions in the planned order" provides a solution for an interface to external assembly
control systems. This is used to transfer progress at the assembly line and other dependent actions
via a standard interface or via an adjusted interface to the SAP System.

The following standard actions are possible: BEMA BOM explosion with availability check,
BFPL Backflush planned order, BOME BOM explosion, COPD Change planned order data
(e.g. sequence number, order quantity), DLPL Delete planned order, FIKM Firm planned order
components, FIRM Firm planned order header, MAAV Availability check with BOM explosion
if necessary, NEMA Availability check without BOM explosion, PRNT Print component list,
RSMA Reset material availability check, SCHE Scheduling planned orders, Execution of
customer-defined actions, ZZXX Customer action.

Using this function, you can execute one or several actions for a series of planned orders
simultaneously. Without this function, you would have to execute these actions individually online
for each planned order. The action control also defines which actions are allowed and the sequence
in which the actions are to be carried out. The date and time of the last action is saved in the
planned order.

Executing actions: To execute actions, you must maintain a report that transfers the customerspecific data for the action. An example exists for this in the main menu of Material Requirements
Planning (MRP) - transaction Execute Action.
To print the planned order component list, the system uses the printer defined in Customizing for
MRP in the work step Procurement Proposals -> Planned Orders -> Define Layout for Component
List.
© SAP AG
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
Prerequisite:
 You define the action key and the action control in Customizing for MRP in the work step
Procurement Proposals. The action key defines the action. The action control key defines which
actions can be carried out and in which sequence the actions should be carried out. Various other
actions can follow an action, or the action can follow other actions.
 Material master record (MRP view): To carry out an action for a material, you must enter the
appropriate action control key in the material master record.

Example: The key 01 was defined. This means actions BOME, NEMA, and, PRNT are allowed.
Sequence: First the BOM has to be exploded. The material availability check can only be carried out
after the BOM explosion. Once the material availability check has been carried out, the system is to
print out the component list.

In the action control, you can define your own actions. Then you can define, for example, that the
current status of every operation in the planned order is an action meaning that you can carry out
your own status management (for example using a BDE scanner).

Technical information: A function module exists (MD_SET_ACTION_PLAF) for Actions in the
planned order, which you can use to execute one or several functions in a planned order. Before you
execute an action, you can change the data of the planned order. This new planned order data is
transferred to the function module of structure MDCD. Before the action is carried out, the system
uses the change indicator (parameter IAENKZ) to check whether the data has actually been
transferred to the planned order. It is also possible to change data without creating a link to other
actions. For more detailed information see Note 44350.
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Backflushing in Make-to-Order Production
Goods receipt to individual
customer stock for sales order
Planned order
for material A:
B
C
D
Component list
Planned order
Receiving storage location
Production line
Goods issue
Issue storage location 1
Goods issue
Issue storage location 2
 SAP AG 2004

Several functions are available for backflushing a sales order to individual customer stock. In these
functions, you must enter the number of the sales order:

The system determines the planned orders that correspond to the sales order:
 If only one planned order is assigned, the system enters this planned order in the appropriate field
when data has been released and the planned order quantity is proposed as a backflush quantity.
 If several planned orders exist for a sales order, then when you release the data the system displays
a dialog box in which you must select the appropriate planned order. This planned order is then
entered in the appropriate field and the planned order quantity is proposed as a backflush quantity.
 If the planned order(s) for the sales order no longer exist(s) because the quantity has been
produced, but you nevertheless want to post a goods receipt (overdelivery), the system explodes
the current, valid BOM.

In the final backflush, the components (with reference to a configured BOM, if required) and the
production activities are backflushed. If you have high volumes to backflush, you can use the
function Separate backflushing processes with or without aggregation to enhance system
performance (only when working with valuated sales order stock/product cost collector).

Postprocessing records are only possible in make-to-order repetitive manufacturing with product cost
collector/valuated sales order stock.

Reporting point backflushing is not possible in make-to-order repetitive manufacturing.
© SAP AG
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
Use: When backflushing large amounts of data, to improve performance you can also aggregate the
backflush and/or the production activity postings when separating the backflushing processes. To do
this, proceed as follows:

Aggregation of goods issue posting:
• In make-to-order repetitive manufacturing, every planned order is exploded separately. The
components which can be aggregated (stock components) are aggregated.
• The goods issues are posted. All identical components are aggregated for posting.
• Dependent requirements for the components are reduced.

Aggregation of production activities:
• In make-to-order repetitive manufacturing, goods receipts are aggregated. Production activities
are calculated in proportion to this total quantity. The routing provides the basis for this
calculation.

Prerequisite:
• In the process control profile (definition in Customizing for Repetitive Manufacturing in
workstep Backflush / assignment in the repetitive manufacturing profile), you set that the
backflush and/or the production activitiy posting is to be aggregated.
• In make-to-order repetitive manufacturing, separation of the backflushing processes is only
supported if you work with a production cost collector (make-to-order repetitive manufacturing
with valuated sales order stock).
© SAP AG
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
The aggregation is carried out when posting the backflush/production activities. The reference of the
components to the assembly is lost during aggregation. After the aggregation, therefore, you have to
carry out any necessary reversal postings using the non-document-based reversal (and not the
document-specific reversal).

The aggregation logic described above for make-to-order repetitive manufacturing is also used if you
backflush in make-to-stock production with reference to a planned order.
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 Collecting costs in a production cost collector (with valuated sales order stock):
For make-to-order production, you can also collect and settle costs that occur in production using a product
cost collector (period-based Controlling). Material stock is valuated, and products go straight from production
into valuated sales order stock.
 If material A, for example, is produced on two production lines, you must create two production versions. The
following options are available for collecting costs:
• 1:1 relationship between product cost collector and production version: costs are collected for each
version (that is, costs incurred in the production of material A, on two production lines, are collected
separately).
• 1:N relationship between product cost collector and production version: costs are collected cross-version
for each material (that is, costs incurred in production of material A, on two production lines, are
collected together).
 Prerequisites:
• Sales orders must be created with a requirements type designed for valuated sales order stock. In
Customizing for Sales and Distribution in the step Basic Functions -> Account Assignment/Costing, you
have to make settings in the requirements class that matches the planning strategy, in the Valuation field,
so that a separate valuation takes place with reference to the sales document (valuated sales order stock).
Since the sales document item does not usually require a cost collector in addition to the production cost
collector, you should enter E in the Account assignment category field. To set the system to automatically
select the correct requirements type in the sales order, you select an appropriate strategy in the material
master. The valuation, on the other hand, shows the value segment in which the material lies. Choose
value = M, so that the values are in the individual customer segment after the backflush.
• Main menu of Repetitive Manufacturing: Create product cost collector for cross-version cost collecting
(Controlling level: Production plant) or for version-specific cost collecting (Controlling level:
Production version). The Controlling-level BOM/routing is not relevant for repetitive manufacturing.
© SAP AG
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Cost Collection at Product Cost Collector
Product
cost
collector
Configurable
material
dit
Cre
Material costs
Components
Debit
$30 000
Balance sheet
account
MM
Sales order
stock (valuated)
$26 000
Debit
Production
activities
Debit
Overhead
Debit
$10 000
Cred
it
$3 000
MM
Sales order
stock (valuated)
$16 000
$43 000
Variance costing
- $42 000
$1 000
Variance costing
Price difference
account for
std price materials 1
$1 000
 SAP AG 2004

Collecting costs in a production cost collector (with valuated sales order stock): If you produce a
large amount of standard products daily (for example, as in the automotive or computer industries), it
is often not necessary to collect the costs per sales order item. Here, you can use a simplified, periodbased cost collection procedure by means of the product cost collector. This also means you reduce
the effort required in Controlling for make-to-order repetitive manufacturing ("lean controlling").
Also, you can only separate the backflushing processes (important for customers who backflush high
volumes) in make-to-order repetitive manufacturing if you work with a product cost collector.

Costs are collected and settled using a product cost collector. Goods issues of the components used
to manufacture the product are debited to the product cost collector. The goods receipt of the product
is credited to the product cost collector. Crediting the product cost collector at goods receipt is linked
to the crediting of the sales order stock (valuated sales order stock). The difference between debits
and credit in the product cost collector is posted to a price difference account at period-end. No
variance calculation (lot size variance, price variance, and so on) takes place.

Other option: Valuation without reference to the sales document (Indicator Evaluation = A in the
requirements class): Here, the material stock is valuated, however, the values are not managed
individually per individual customer stock. They are managed together with the warehouse stock for
all individual customer stocks. Use: If you produce products with a large number of variants each of
the same value more or less or if you do not produce products with variants but still want to use the
make-to-order production (for example, as the material is not to be produced to stock for cost
reasons). Prerequisite: In Customizing for Sales and Distribution in the step Basic Functions ->
Account Assignment/Costing, you have to make settings in the requirements class that matches the
planning strategy, in the Valuation field, so that a separate valuation takes place without reference to
the sales document (valuated sales order stock).
© SAP AG
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Valuation Strategy for Valuating Sales Order Stock
of Configurable Materials
Product
cost
collector
Standard price according
to customer exit COPCP002
Standard price according to
sales order costing
$30 000
$10 000
MM
$3 000
- $42 000
$43 000
$1 000
Credit
Sales order
stock (valuated)
Standard price according to
preliminary costing for
the production order
Standard price according to
costing with no ref. to order
$26 000
Debit
Configurable
material
Standard price according to manual
entry in the material master
What amount is credited to the product cost collector/debited to the sales order
stock for configurable materials?
 SAP AG 2004

Valuation strategy in requirements class: controls how the standard price is determined when
using valuated sales order stock. The standard price is defined dynamically on first goods receipt. If
further goods receipts are posted for the same sales order item, these goods receipts are valuated
using the same standard price.
In the event of no goods receipt being posted, the standard price is defined according to a fixed,
defined strategy sequence:
1. Standard price according to customer exit COPCP002 material valuation for valuated sales order
stock,
2. Standard price according to sales order costing (the quantity structure of each sales order item is
costed separately. This means that stock values for the same material can be differentiated per
sales order item),
3. Standard price according to preliminary cost estimate for the production or process order (not
relevant in Repetitive Manufacturing),
4. Standard price for non-allocated stock according to costing, without reference to the order in the
material master (all individual stocks are given the same stock value),
5. Standard price for non-allocated stock, manually created in the material master.
If no appropriate value exists, the system proceeds to the next strategy, and so on. If, on the other
hand, you always want to valuate valuated sales order stock with the standard price for nonallocated stock, then you must set the corresponding indicator in Customizing for Requirements
Class.
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Period-End Closing: Product Cost Collector
(Valuated Sales Order Stock)
1. Process cost allocation
Product cost
collector
2. Recalculation of act. prices
3. Surcharges
4. Work in process
5. Variance costing
6. Settlement
 SAP AG 2004

In the CO period-end closing for the product cost collector, you can:
1. Carry out process cost allocation.
2. Revaluate activities that were debited with cost objects, according to the actual activity price.
3. Carry out the overhead calculation.
4. Determine goods in process (not for make-to-order oriented repetitive manufacturing, as here the
reporting point backflush is not available to backflush goods in process).
5. Carry out a variance costing (not for make-to-order repetitive manufacturing).
6. Carry out settlement: In period-end closing settlements, the difference between credits and debits
in the product cost collector is posted to a price difference account.

The period-end closing and details of the cost object controlling for sales orders (costing for
sales orders of valuated sales order stock) are included in course AC515 (Cost object
controlling for sales orders).
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Backflush: Summary
 Activities when backflushing
 Scrap
 Reversing a backflush
 Backlogs from backflushing
 Separation of backflushing processes
 Reporting point backflush
 Cost collection
 Period-end closing
 SAP AG 2004
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Backflush Exercises
Unit:
Backflush
Topic: Yield and Scrap Backflush
At the conclusion of this unit, you will be able to
•
Carry out backflushing in repetitive manufacturing
•
Post the assembly scrap
In your plant 1200, you produced the PC motherboard on the
assembly production lines and the personal computer on the final
assembly production line.
You work on the production lines and carry out the tasks you
receive from your foreman.
You produce according to the operational method sheets and you
are responsible for carrying out the backflush.
You now have the task of backflushing the quantities produced in
the R/3 System.
8-1
A total of 90 motherboards were produced to stock on the T-L3## assembly
production line. It is your job to carry out the backflush.
8-1-1 Backflush 90 pieces for the motherboard (material number T-B10##) on
production line T-L3## in plant 1200.
Before you start the posting by choosing Save, choose Enter and then
answer the following questions:
8-1-2 Which storage location is to be used for the goods receipt for the assembly
to backflush? How does the system determine this receiving storage
location?
______________________________________________________
8-1-3 Choose Post with correction. Which components are backflushed in the
final backflush?
______________________________________________________
8-1-4 Where does the system determine which components are to be backflushed
in make-to-stock repetitive manufacturing?
______________________________________________________
© SAP AG
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8-1-5 From which storage location are the components issued for the assembly?
How does the system determine this issue storage location?
______________________________________________________
______________________________________________________
______________________________________________________
8-1-6 Choose Post to post the backflush.
Which main actions are carried out by the system in this backflush?
______________________________________________________
______________________________________________________
______________________________________________________
8-2
On production line T-L3##, you have also produced one T-B10## assembly which
is faulty.
8-2-1 Therefore, post an assembly scrap of 1 piece for the T-B10## assembly on
production line T-L3## (production version 0001). Proceed as before. Note
however, that you are performing a scrap posting.
8-2-2 After posting, note the status line in the lower screen area. What was
posted?
O Goods issue for the components
O Production services that were required
O Goods receipt for assembly to warehouse
8-3
Check in the system to see how the planned quantities (planned orders) have been
reduced by the warehouse receipt in the backflush.
To do this, access the planning table using a selection through production line as
in the previous exercise: In plant 1200, choose production line T-L3##.
How have the planned quantities (planned orders) changed?
____________________________________________________________
After the assemblies have been produced, the final assembly
can begin. Here, those components that are not produced in
advance in assembly production have to be transferred from
the central storage warehouse to the production line, using
the pull list. However, staging of the components on the final
assembly lines is not necessary here.
© SAP AG
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Exercises
Unit:
Backflush
Topic:
Postprocessing and Document-Based
Reversal
At the conclusion of this unit, you will be able to
•
•
Postprocess backorder backflushing in the case of
withdrawal errors
Perform a document-based reversal
Your plant 1200 produces PC motherboards on the assembly
production lines.
As the production scheduler, you yourself also perform
backflushes for the boards produced. You notice a problem.
During the component withdrawal, components are physically
used up that are not available in sufficient quantity for a goods
issue backflush at the time of the subsequent backflush in the
system. For this reason, you perform backlog processing.
Also, someone has mistakenly entered an incorrect backflush,
which you reverse based on a document.
9-1
Before you begin, check which form of backlog processing is supported in the
system for material T-B10## in plant 1200.
9-1-1 Which repetitive manufacturing profile has been entered in the material
master for assembly T-B10##?
_____________________________________________________
9-1-2 Now check the repetitive manufacturing profile in Customizing to see how
backlog processing is handled in this particular profile.
______________________________________________________
______________________________________________________
______________________________________________________
9-1-3 Are these settings useful?
______________________________________________________
______________________________________________________
© SAP AG
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9-2
Perform a backflush for plant 1200 of 200 pieces of assembly T-B10## (production
line T-L3##). Use the backflush transaction for this assembly backflush, and
choose the Post key.
9-2-1 A message informs you of withdrawal errors. Which components have been
affected, and how much is the shortfall in the warehouse stock for each
component?
Comp. 1: _______ by _______ pieces in the warehouse _______
Comp. 2: _______ by ______ pieces in the warehouse _______
Comp. 3: _______ by ______ pieces in the warehouse _______
Confirm with Enter.
9-2-2 The system displays an information message informing you that backlogs
have been generated (in a postprocessing list). Confirm this message with
Enter, and note that the system performs the posting.
9-3
Call the postprocessing list in the menu for backflush for repetitive manufacturing
for line T-L3## in plant 1200. Answer the following questions.
9-3-1 Do the components from 9-2-1 exist in the document?
____________________________________________________
9-3-2 Are the entire quantities or the shortfall quantities from 9-2-1 noted here?
____________________________________________________
9-4
Call the current stock/requirements list for component T-B7## (plant 1200).
Make sure that a requirement exists for this component in the production storage
location PL03 with the PostProc indicator because otherwise the goods issue for
the assembly cannot be posted during backflush.
9-5
In the meantime, an employee subsequently posts a goods receipt of over 200
pieces for component T-B7## in plant 1200.
Perform this goods movement in the menu for Materials Management (Inventory
Management), posting a Goods Receipt → Other (receipt without purchase order
into unrestricted-use stock for storage location PL03, movement type 501).
Confirm the information message that appears during posting and then Post the
document.
© SAP AG
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9-6
Call the postprocessing list again for line T-L3## in plant 1200.
9-6-1 Select the document for the assembly that contains component T-B7## and
select Postprocess Selected Postprocessing Record.
On the following screen, select the line containing component T-B7## and
choose Post.
Look at the message log on the next screen. Note: Only the situation
concerning the missing parts for T-B7## has been resolved.
9-6-2 Exit the log using the Back button. Does the postprocessing list still contain
item T-B7##?
______________________________________________________
Exit the postprocessing list.
9-7
The previous backflush was caused by a misunderstanding. Reverse the backflush
and resolve the postprocessing situation. Proceed as follows:
9-7-1 From the menu for backflush in repetitive manufacturing, call the
transaction for reversals for material T-B10## (plant 1200, production
version 0001).
Using today’s date and the selection Make-to-Stock Production, execute
the report and select the appropriate document in the next screen (note:
Familiarize yourself with the posting date, number of pieces, and existence
of postprocessing records) and choose Reverse.
Read the F1 help for the information message that appears, and look at the
results from question 9-1-2 again. Is extra effort going to be required
because of the postprocessing records?
______________________________________________________
Confirm the help and the information message and execute the reversal.
9-7-2 Call the postprocessing list again and manually delete the appropriate
document.
© SAP AG
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Exercises
Unit: Backflush
Topic: Make-To-Order Production
At the conclusion of this unit, you will be able to
•
Perform a sales order-based backflush
•
Assign serial numbers during this kind of backflush
On the final assembly production lines, 90 PCs (material number
T-F10##) have already been produced for the customer.
Production at end-product level was not carried out as make-tostock production, but as make-to-order production to individual
customer stock.
As the production scheduler, you perform backflushes for the PCs
produced so far.
10-1
Perform a sales order-based backflush.
10-1-1 First, take a note of the sales order number and the sales order item
number for the first sales order you created in the first planning exercise.
Note: You can find the sales order number from the current
stock/requirements list for material T-F10## (or from the planning table).
Menu path for the current stock/requirements list:
Logistics Production MRP
Evaluations Stock/Requirements List
Field name or data type
Values
Material
T-F10##
Plant
1200
Choose Enter.
Enter the number of the sales order here:
______________________________________________________
Enter the number of the sales order item here:
______________________________________________________
© SAP AG
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10-1-2 Backflush 90 pieces in plant 1200 for the sales order above.
Make sure that you carry out a sales order backflush so that stock is posted
to the individual customer stock.
Before you start the posting by choosing Save, choose Enter and then
answer the following questions:10-1-3 A dialog box entitled Planned
order selection appears. Why are two planned orders displayed in the
backflush?
______________________________________________________
______________________________________________________
10-1-4 In the dialog box, choose the planned order that was produced on production
line T-L1## using the production version 0001and confirm your selection
by choosing Enter.
Choose Post with correction. Which components are backflushed in the
final backflush?
______________________________________________________
______________________________________________________
______________________________________________________
10-1-5 Where does the system receive the information on which components to
backflush in make-to-order repetitive manufacturing?
______________________________________________________
10-2
Choose Post to post the backflush.
In the Maintain serial numbers dialog box that appears next, you can assign serial
numbers for the personal computers. Choose Create serial numbers
automatically, so that the number assignment occurs automatically, then confirm
with Enter.
In the next dialog box (Withdrawal Errors), the system points out that various
components cannot be backflushed because there is not sufficient stock in storage
location PL01 on the production line. In the previous exercise, you already used the
procedure for resolving this issue.
Confirm by choosing Enter twice.
Which main actions are carried out by the system in this backflush?
____________________________________________________________
____________________________________________________________
© SAP AG
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Solutions
Unit:
Backflush
Topic: Postprocessing and Document-Based Reversal
9-1
9-1-1 Menu path:
Logistics → Production → Master Data → Material Master → Material
→ Display → Display Current
MRP 4 view
The repetitive manufacturing profile 0002 has been entered.
9-1-2 Menu path:
Transaction OPP3 (Customizing for Repetitive Manufacturing)
Control Data → Define Repetitive Manufacturing Profiles → 0002
On the Control data 1 tab page, you can see that cumulated postprocessing
records were generated. However (for performance reasons) the individual
records are not displayed in detail. The transaction expects a correction,
however this entry is optional (that means, the relevant message is only a
warning message and not an error message).
9-1-3 These settings are a useful variant because, in cases where errors arise,
postprocessing records are constantly being generated, whether the
backflusher reacts directly to the warning message or ignores it.
9-2
Menu path:
Logistics → Production → Repetitive Manufacturing → Backflush → REM
Backflush
9-2-1 T-B7##, T-T7## in the PL03 production storage location; the quantities
vary (the difference is nearly 200 pieces in each case).
9-2-2 - No solution necessary -
9-3
Menu path:
Logistics → Production → Repetitive Manufacturing → Backflush →
Postprocess → Postprocessing List
9-3-1 Yes.
9-3-2 The complete quantities from the backflush posting are entered.
9-4
© SAP AG
Menu path:
Logistics → Production → MRP → Evaluations → Stock/Requirements List
TSCM32
7-56
9-5
Menu path:
Logistics → Materials Management → Inventory Management → Goods
Movement → Goods Receipt → Other
9-6
Menu path:
Logistics → Production → Repetitive Manufacturing → Backflush →
Postprocess → Postprocessing List
9-6-1 - No solution necessary 9-6-2 No.
9-7
Menu path:
Logistics → Production → Repetitive Manufacturing → Backflush → Reverse
9-7-1 When you perform the reversal, the system issues a warning message
informing you of the existing postprocessing records. After you have read
the information in the F1 help, confirm the message and the following
message with Enter.
As you can see from 9-1-2, no individual processing records arise
according to the Customizing settings. As a result of this, when you reverse
postprocessing records, you must manually delete all relevant
postprocessing records.
9-7-2 Menu path:
Logistics → Production → Repetitive Manufacturing → Backflush →
Postprocess → Postprocessing List
Select the relevant document and activate “Delete Selected Postprocessing
Records”.
© SAP AG
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Solutions
Unit: Backflush
Topic: Make-To-Order Production
10-1
10-1-1 You can find the sales order numbers in the stock/requirements list (data for
the MRP element) or the planning table (details for the MRP element).
10-1-2 Menu path:
Logistics  Production  Repetitive Manufacturing
Backflush  REM Backflush
Backflush type: Assembly backflush
Choose the Make-to-order tab page and enter the following data:
Field name or data type
Values
Backflush quantity
90 pieces
Sales order
Enter the sales order number
you noted
Sales order item
Enter the sales order item
number you noted
Plant
1200
Before you start the posting, choose Enter.
10-1-3 During the backflush, two planned orders are displayed because, for this
sales order, planned orders were scheduled to two production lines and
therefore to two production versions. As the backflush in make-to-order
production is carried out with reference to the planned order (as opposed to
the backflush in make-to-stock production), you have to select the
appropriate planned order in this case.
10-1-4 When backflushing for the sales order, components T-B10##, and T-B20##
through T-B90## are backflushed.
10-1-5 When backflushing for the sales order, the system read the components of
the corresponding planned order (planned order backflush) and not the
BOM.
© SAP AG
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10-2
During the backflush, the system not only performed the posting of production
services, but also posted the goods receipts for the end product into the sales order
stock and performed a backflush for each component for which a posting without
errors was possible.
Refer to the second information message for this information.
© SAP AG
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Evaluations
Contents:
 Reporting point overview
 Backflushing documents
 BW statistics (Business Information Warehouse)
 LIS statistics (Logistics Information System)
 Controlling reports (variances, surcharges)
 SAP AG 2004
© SAP AG
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8-1
Evaluations: Course Objectives
At the conclusion of this unit, you will be able to:
 Select suitable evaluation procedures and evaluation
tools, in order to analyze the data arising from the
production process.
 SAP AG 2004
© SAP AG
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8-2
© SAP AG
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8-3
Evaluations: Business Scenario
 In your plant 1200 you produced the PC assembly
T-B10## on production line T-L3##
 Now you want to analyze the production process
data
 SAP AG 2004
© SAP AG
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8-4
Reporting Point Overview (Work in Process)
Reporting point:
Work center
Production line:
line3
Material:
10
20
C-1112
PC-A Assembly
PC-T Test
5 pieces
3 pieces
Material:
10
20
0815
47-11 Assembly
47-12 Test
3 pieces
2 pieces
 SAP AG 2004

The reporting point overview gives you a statistical overview of all the materials for a production
line. For each material with reporting points, the list contains those quantities that have already
passed the reporting point at the current point in time, but have not yet been backflushed in the final
backflush. The goods receipt has not yet been posted for these quantities.
Example: At the first reporting point, 5 pieces, and at the second reporting point, 3 pieces, have
passed through and been backflushed. Final backflush has not yet been carried out as the product is
still being processed and has not yet been finished.
As soon as final backflush is carried out, the backflush quantities at the previous reporting points are
reduced by the final backflush quantity. For example, if 2 pieces were backflushed in the final
backflush, the backflush quantities at the previous reporting points would be reduced by 2 pieces.
This would result in a backflush quantity of 3 pieces at reporting point 1 and a backflush quantity of
1 piece at reporting point 2.
© SAP AG
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8-5
Backflushing Documents
Reverse
Material
Plant
Version
Proc.type
User
Date
Reporting
point:
Quantity
Doc. log
header no.
Item
Material
doc.
Activity
backflush
Reversal
Reporting Reversal
point doc.
Production method: Repetitive manufacturing
C-1112
Z
0000000603
0000000603
0000000603
0000000603
1200
Layer
0001
0002
0003
0004
0001
05.22.02
49007470
30
10 pc
39692
0000000111
0000000112
C
C
C
C
C
 SAP AG 2004

In the Repetitive Manufacturing backflush, a backflushing document is created that summarizes the
individual documents. Individual documents can be: either material documents for the goods
receipt of an assembly and the goods issue of components, activity documents, or postprocessing
documents for unsuccessful goods issue postings.

The reversal indicator shows whether a document has been reversed and how this has been done as
follows: document has not been reversed, document is reversed, document is a reversal document,
document has been partially reversed, document created using postprocessing records.

Processing type: key that identifies the processing type used for backflushing in Repetitive
Manufacturing:
B (backflush): goods receipt, goods issue and activity backflush; N (postprocessing): postprocessing
unprocessed or incorrect backflushes; Z (reporting point backflush): goods issue for reporting point;
R (goods receipt now, and goods issue later): post goods receipt immediately and create
postprocessing records for goods issue items; C (resetting reporting points): posting reporting point
quantity to scrap; S: reversal; E: high-performance backflush; A: only activity posting; U: unplanned
consumption message; V: scrap message; W: activity posting reporting point; X: unplanned
consumption message reporting point; Y: scrap message reporting point; I: Service posting after last
reporting point; J: Unplanned consumption report after last reporting point; K: scrap message
according to last reporting point.
© SAP AG
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8-6

All kinds of reporting systems are widely spread throughout the current business environment.
However, many of these systems are not yet able to deliver the information required for complex
decision making. There is often a need for a complete solution which encompasses both crosssystem and company-wide reporting.

Data Warehouses, such as mySAP Business Information Warehouse (BW), have been specially
designed for these environments. They are decision support systems for the modern business
environment. BW is an OLAP (Online Analytical Processing) system. It presents users with
information in a form that enables cross-system and cross-application reporting.

Some important features of the BW architecture are rapid implementation (delivery of
preconfigured BW objects using Business Content such as extractors, work folders, roles), flexibility
(multilevel architecture, for example, for extraction, data modelling, analysis, and presentation),
openness (for example, import/export of MS Word/Excel data and so on).
© SAP AG
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Logistics Data for mySAP BW
Extractors
Source Data
R/3 Customizing:
 Generate DataSource
 Choose
selection fields
LIS
LO
CO-PA
FI-SL
 Other settings
(e.g. delta
updates)
Information
data
InfoCubes
 SAP AG 2004

You can use the SAP R/3 Customizing to generate extractors for standard and customer-specific
structures. Extractors take their data from different source systems, for example, R/3, R/2, or from
non-SAP systems.

The extractor is used to define the structure of the InfoCube (multidimensional table structures in
which the data is stored physically), as well as control the initial and delta updates. The source data
(movement data that is transferred using the extraction structure and the transfer structure) is
converted into the information data (communication structure), from which the InfoCubes are
generated.

Updates in Logistics can be performed using LIS data structures or a direct LO data extraction.
There are other update options using CO-PA (Profitability Analysis in Controlling) or FI-SL (Special
Purpose Ledger in Financial Accounting).

InfoCubes contain the data types "key figures" and "characteristics". The various characteristics are
defined using the various dimensions of the InfoCube. One key figure is then saved for a unique
combination of characteristic value assignments (in other words, for a single element of the cube)
such as division, region, and customer group (for example, sales, working hours).

For more information on extraction, see the course BW220.
© SAP AG
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8-8

In the Repetitive Manufacturing backflush, various data in the Logistics Information System (LIS) is
updated. You can carry out LIS analyses on this data from the main menu for Repetitive
Manufacturing. For example, the following analyses are possible:

Goods receipt statistics: The system creates statistics for the updated actual production and scrap
quantities. The planned quantities are also included in the statistics. To have the planned quantities
included in the goods receipt statistics, you must trigger the planned quantity (planned order
quantities from planning) update before accessing the statistics. You should schedule this function to
take place at regular intervals as a background job. You set the interval for data updates in
Customizing for Repetitive Manufacturing in the IMG activity Actual data entry -> Maintain Global
Settings for Confirmation and LIS.

Material consumption statistics: The system creates statistics for the updated component
requirements and the actual component consumption.

Product costs statistics: The system evaluates the updated product costs.
© SAP AG
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8-9
Controlling Reports
Planned Actual Var. (%) (%)
Cost elements
410000
619000
620000
655100
890000
Consumption: trading goods 160 000
Dir. Int. Act. Alloc. Prod
30 000
Dir. Int. Act. Alloc. Mach
40 000
16 000
Ovhd surcharge raw material
Consumtn semi-finished prod. 180 000
170 000
33 000
41 000
17 000
175 000
Debits
426 000
436 000
895000
Factory output production
426 000
Credit
426 000
Total
426 000
10 000
Material: C-1112
Actual quantity: 60 pieces
 SAP AG 2004

Various CO reports can be created within Repetitive Manufacturing for analyzing production costs.
© SAP AG
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8-10
Evaluations: Summary
 Reporting point overview
 Backflushing documents
 Business Information Warehouse
 LIS statistics
 Controlling reports
 SAP AG 2004
© SAP AG
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8-11
Exercises
Unit: Evaluations
At the conclusion of this unit, you will be able to
• Use some basic types of evaluations for repetitive
manufacturing
In your plant 1200, you produced the PC motherboard on the
assembly production lines and the personal computer on the final
assembly production line.
As the production scheduler, you are responsible for
implementing the planning specifications from the production
planner.
In this role, it is your task to carry out various evaluations
(planned/actual comparison, material consumption analysis).
11-1
In the following, take note of the comparison between the planned and actual
production data for the motherboard.
You have already updated the planned quantities from the planning table as a
statistic in an earlier exercise. The system updates the actual data as a statistic
automatically during the backflush.
Carry out the planned/actual comparison for the motherboard (material number TB10##):
Menu path:
Logistics → Production → Repetitive Manufacturing
Evaluations → LIS Statistics → GR Statistics
Field name or data type
Values
Plant
1200
Material
T-B10##
Production line
T-L3##
Before you execute the report, you should maintain the display settings for the list
of results:
Choose User settings and your SCM320-## user in the dialog box that then
appears. Confirm your user with Enter.
Choose Key figures and then Choose key figures (button below left). Add Planned
order qty to the selection and confirm with Enter.
Choose Save to save the user-specific settings for the results list of the goods
receipt statistics. Exit this template using the Back button.
© SAP AG
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When you define the analysis period, ensure that your updated quantities are partly
in the future.
Carry out the evaluation (good receipt statistics). To do this, start the report (F8).
After the analysis is complete, exit the statistics using the Back button without
saving.
11-2
Now carry out a material consumption analysis for the components of the TB10## material.
Menu path:
Logistics → Production → Repetitive Manufacturing
Evaluations → LIS Statistics → Material Consumption
Field name or data type
Values
Plant
1200
Material
T-B10##
Execute the report (F8).
After the analysis is complete, exit the statistics using the Back button without
saving.
© SAP AG
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Solutions
Unit: Evaluations
11-1
- No solution necessary 11-2
- No solution necessary -
© SAP AG
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© SAP AG
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9-1
Conclusion
You are now able to
 Position repetitive manufacturing correctly within
the complete mySAP SCM environment (demand
management, material requirements planning,
sales order processing, and so on)
 Work with or implement repetitive manufacturing
with its essential basic functions
 Use and comprehend details of the Repetitive
Manufacturing functions
 Consider the integration relationships of repetitive
manufacturing
 Use self-study to learn further special functions
 SAP AG 2004
© SAP AG
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9-2
Recommended Follow-up Courses
Follow-up courses
 SCM350 (KANBAN)
 PLM420 (QM in Discrete Manufacturing)
 AC510 (Cost-object Controlling for Products)
 AC515 (Cost-object Controlling for Sales Orders)
 SAP AG 2004
© SAP AG
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Options for Further Study
 Go through the exercises using IDES data or your own data
 Read the relevant sections in the online documentation
 Read the relevant sections in the IMG documentation
 Read release notes
 SAP AG 2004
© SAP AG
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Appendix
 This section contains supplementary material
to be used as reference
 This material is not part of the standard course
 The course materials covering the topic TaktBased Flow Manufacturing in R/3 are contained
entirely in this section of the material: The
units Material Staging, Backflush, and
Evaluations are identical to those in standard
repetitive manufacturing. The differences
concerning the Master Data and Planning are
covered in the subsections in the appendix.
 SAP AG 2004
© SAP AG
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10-1
SCM-REM Exercise Materials: BOM T-F10##
Maxitec-R 375 PC
R-1000
(PROD, T-F10##)
(1200, 0, _ )
Item
0010
1
0020
1
Cable
Motherboard
0030
1 0040
1 0050
TFT monitor
Keyboard
1
Disk drive
0060
1
0070
Hard drive
0070
1
PC casing
R-1130
R-1120
R-1130
R-1140
R-1150
R-1160
R-1170
(HALB, T-B10##)
(1200, 0, 2 )
(HAWA, T-B20##)
(1200, 1519, 2 )
(HAWA, B30)
(1200, 2009, 2 )
(HAWA, T-B40##)
(1200, 1719, 2 )
(HAWA, T-B50##)
(1200, 9789, 2 )
(HAWA, T-B60##)
(1200, 1495, 2 )
(HAWA, T-B70##)
(1200, 1644, 2 )
1
CD-ROM
R-1180C
(HAWA, T-B80##)
(1200, ?, 2 )
0010
1
CD-ROM
Item
0010
1
0020
RAM
Processor
R-1210
(HAWA, T-TE##)
(1200, 2100, 2 )
2
R-1220
(HAWA, T-T6##)
(1200, 3700, 2
0030
1
BIOS
0040
R-1250C
1
(HAWA, T-TC##)
(1200, ?, 2 )
Cooling unit
0080
R-1230
R-1240
(HAWA, T-T7##)
(1200, 200, 2)
(HALB, T-B7##)
(1200, 200, 2 )
1
Modem
R-1190C
(HAWA, T-B90##))
(1200, ?, 2 )
0010
Cooling element
1
0020
1
Ventilator 5 V
R-1310
R-1330
(HAWA, T-T8##)
(1200, 200, 2 )
(HAWA, T-T9##)
(1200, 200, 2 )
0010
1
Casing
R-1260C
(HAWA, T-TB##)
(1200, 200, 2 )
Legend:
0020
1
Boards
R-1270C
(HAWA, T-TD##)
(1200, 200, 2 )
(IDES template material number)
(Material type, material number, course (## = 00 - 30))
(plant, stock quantity, single/collective indicator)
 SAP AG 2004
© SAP AG
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SCM-REM Exercise Materials: BOM T-F13##
Maxitec-R 375 PC
R-1000
(PROD, T-F13##)
(1200, 0, _ )
Item
0010
Motherboard
1
0020
1
Cable
R-1112
R-1120
(HALB, T-B11##)
(1200, 0, 2 )
(HAWA, T-B20##)
(1200, 1519, 2 )
0030
1 0040
1 0050
1
0060
1
0070
0070
1
1
Keyboard
TFT monitor
R-1130
(HAWA, B30)
R-1140
R-1150
R-1161
R-1170
R-1180C
(HAWA, T-B40##)
(1200, 1719, 2 )
(HAWA, T-B50##)
(1200, 9789, 2 )
(HAWA, T-B60##)
(1200, 1495, 2 )
(HAWA, T-B70##)
(1200, 1644, 2 )
(HAWA, T-B80##)
(1200, ?, 2 )
(1200, 2009, 2 )
Disk drive
Hard drive
PC casing
CD-ROM
0010
1
CD-ROM
Item
0010
1
0020
RAM
Processor
R-1212
(HAWA, T-TE##)
(1200, 2100, 2 )
2
R-1220
(HAWA, T-T6##)
(1200, 3700, 2
0030
1
BIOS
0040
R-1250C
1
(HAWA, T-TC##)
(1200, ?, 2 )
Cooling unit
0080
R-1230
R-1240
(HAWA, T-T7##)
(1200, 200, 2)
(HALB, T-B7##)
(1200, 200, 2 )
1
Modem
R-1190C
(HAWA, T-B90##))
(1200, ?, 2 )
0010
Cooling element
1
0020
1
Ventilator 5 V
R-1310
R-1330
(HAWA, T-T8##)
(1200, 200, 2 )
(HAWA, T-T9##)
(1200, 200, 2 )
0010
1
Casing
R-1260C
(HAWA, T-TB##)
(1200, 200, 2 )
Legend:
0020
1
Boards
R-1270C
(HAWA, T-TD##)
(1200, 200, 2 )
(IDES template material number)
(Material type, material number, course (## = 00 - 30))
(plant, stock quantity, single/collective indicator)
 SAP AG 2004
© SAP AG
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© SAP AG
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© SAP AG
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 In earlier releases a run schedule header had to be created in repetitive manufacturing, which grouped the
general data such as product cost collector and production versions. Getting rid of the run schedule header
reduces the effort involved in maintaining the master data for repetitive manufacturing.
The indicator Run schedule header allowed, which previously had to be set when creating a production
version, has been renamed Repetitive manufacturing allowed. This indicator allows the production version
for repetitive manufacturing.
When creating run schedule headers, an inspection lot was previously created automatically. In future you will
be able to create the inspection lot in the production version, using the function Inspection lot processing
(transaction MFPR).
 Effects of the data transfer: If you only work with one valid run schedule header, there are generally no
processing or conversion problems. Basically, no run schedule headers are deleted. There are three different
cases for converting run schedule headers:
 1. A run schedule header that is no longer valid at the time of the release change, is automatically replaced
by the corresponding production version. This is possible because a run schedule header only belongs to
exactly one production version. Existing reporting point files, inspection lots, and sample withdrawals will
in future refer to the production version. The original run schedule header is not deleted, but is no longer of
importance for the functions in repetitive manufacturing.
 2. A run schedule header that is no longer valid at the time of the release change, remains in the system. If
the run schedule header has not yet been completed, that is if it has not yet been calculated in Controlling,
you can still make postings to this run schedule header. However, you can no longer change the run schedule
header, you can only set the deletion indicator with the function Change run schedule header (transaction
MF02).
 3. A run schedule header, which lies completely in the future at the time of the release change, cannot easily
be dealt with by the system. Therefore, postprocessing is necessary with such run schedule headers.
© SAP AG
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© SAP AG
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Distribution Key: Daily Staging of
Components/Daily Output Quantities
R/3
 Distribution key for component consumption (in BOM item
of component)
 Distribution key for yield (in production version of
assembly)
 SAP AG 2004

Using the distribution key for component consumption in R/3: Using the distribution key for
component consumption, in MRP for repetitive and flow manufacturing, you can plan the daily
staging of partial quantities, distributed over the order runtime.
The distribution key determines how the quantities required for production are distributed in partial
quantities over the runtime of the planned order. It therefore determines the relationship between
time and component consumption.
If you specify a distribution function for a component, the system creates several planned orders
according to the distribution function which cover the partial quantities of the complete dependent
requirement at various dates within the runtime of the planned order.
 Prerequisite: Enter a distribution key in the BOM item of the component.

Using the distribution key for quantities produced in R/3: Here, in MRP for repetitive
manufacturing, the system can represent a daily yield of partial quantities distributed over the order
runtime. The distribution key determines how the production quantities are to be distributed into
partial quantities over the runtime of a planned order. In the current stock/requirements list, the
system displays daily planned order quantities (each with the same planned order number) as
distributed yields. However, in the planning table, the system does not display daily yields. The
distribution key determines the relationship between time and yield.
 Prerequisite: Enter a distribution key in the production version of the assembly.
© SAP AG
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Continuous Input/Output (1)
APO
Case 1
Case 2
Case 3
Case 4
Operations
Planned order
Product A
10
10
20
20
10
20
10
20
Dependent
reqmts
Discrete input,
discrete output
B
A
Final assembly
C
D
Continuous input,
discrete output
Assembly manufacturing
Discrete input,
continuous output
Continuous input,
continuous output
Continuous output
Discrete output
Continuous input
Discrete input
Height of the triangle: Receipt or requirement quantity
Gradient of triangle: Production rate (quantity per time)
 SAP AG 2004

Use: The aim of continuous input/output is to enable component production or component external
procurement to overlap with the requirements (for example, for long orders). Continuous
input/output is exact to the second (in other words, absolutely continuous).

Prerequisite:
 In the R/3 BOM in the relevant BOM item for the assembly/component, make an entry on the
Basic Data tab page in the Distribution Key field. When using APO: If you have entered a
distribution key at this point in R/3, then the R/3-APO interface in APO-PPM (logical input
component) is automatically copied as consumption type C (continuous consumption) instead of S
(consumption at start of activity) or E (consumption at end of activity).
 In the R/3 production version for the end product/assembly, maintain a distribution key for the
quantities produced (specifies that production quantities are distributed time-related in partial
quantities over the runtime of a planned order, production order, or process order. Also specifies
how this is achieved). When using APO: If you have entered a distribution key at this point in R/3,
then the R/3-APO interface in APO-PPM (logical input component) is automatically copied as
consumption type C (continuous consumption) instead of S (consumption at start of activity) or E
(consumption at end of activity).
© SAP AG
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Continuous Input/Output (2)
APO
Case 1
Product
A
10
10
Case 2
20
20 Product B
10
10
20
Discrete output
also for product B
A
B
C
Case 3
20
10
10
10
20
20
10
20
20
Case 4a
20
Case 4b
Continuous output
also for product B
10
Final assembly
D
Overlapping production Case 4
Planned order for product B if
operation 20 was longer than
operation 10 for product A
Assembly manufacturing
 SAP AG 2004
© SAP AG
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Continuous Input/Output: Offset
APO
Case 4
10
20
Planned order product
A
10
20
Offset
when using (lead-time offset)
an offset
(lead-time offset)
10
10
Planned order product B
10
10
 Problem in case 4: Continuous input of product A (end product), but also
continuous output of product B (assembly): Final assembly is dependent on the
fact that assemblies are available at the same time as production
B
A
Final assembly
C
D
Assembly manufacturing
 SAP AG 2004

Offset: Using the offset, you can move the dependent requirement date for a specific component.

Prerequisite: In the R/3 BOM in the relevant BOM item for the assembly/component, enter a
positive value on the Basic Data tab page in the Operation lead time field. When you use APO, this
value is copied into the Offset field in the R/3-APO interface in APO-PPM (logical input
component). If you have entered a negative lead time, the system also copies a negative offset.
© SAP AG
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
Determining alternative means of procurement: During planning, the APO system selects sources
of supply as follows: 1. Quota arrangement: Quoted procurement alternatives are treated with
priority. 2. Priority (highest priority = 0): If more than one supply source can deliver on time, the
system selects the supply source that has the highest priority. 3. Costs: If there are several supply
sources with the same priority, the system takes account of the costs. 4. Observance of deadlines: In
the production planning run, the system selects the supply source that can deliver the required
quantity on time. If the supply source selected according to the quota arrangement, priority, and costs
cannot deliver the product on time, the system chooses the next best procurement alternative using
the quota arrangement, priority, and costs, and checks this source of supply to see whether it can
deliver on time. Observance of deadlines is therefore a "hard" condition ("hard" constraint). If none
of the available procurement alternatives can keep the deadline, the order is created for a later date.

Prerequisite: Alternative sources of supply exist for the product (for in-house production - different
PPMs, for external procurement - different transportation lanes in the Supply Chain Engineer by
copying various purchasing info records, scheduling agreements, and/or contracts from R/3).
 Maintain the priority of the product-plan assignment in the PPM.
 You have maintained the procurement costs for each alternative:
­ For in-house production you maintain the costs in the PPM (Goto -> Costs). You can maintain
costs for the actual procurement operation (Single-level costs) and for the entire procurement
operation as of this level (Multilevel costs). Single-level costs are used exclusively in SNP
optimization for valuating a routing. Multilevel costs are used in PP/DS for selecting the source
of supply (ensure that the costs are comparable for all production levels!). The costs do not have
to be entered in a specific currency, or even have anything to do with the actual costs. A
comparison is only made between the alternatives for a product.
­ For external procurement and stock transfer, you maintain the costs for the transportation lanes
created manually, in the Supply Chain Engineer. If you have copied purchasing info records,
© SAP AG
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scheduling agreements, and/or contracts from the R/3 system, the costs maintained in these
(purchasing prices) are displayed directly in the external procurement relationships. However, at
any time you can maintain/change the priority and costs in the transportation lane, from the
external procurement relationship. SNP procurement costs from the product master record
(Procurement view) play no role in PP/DS.
 You can use the BAdI (Business Add-In) /SAPAPO/PWB_SOS to influence determination of the
sources of supply.
© SAP AG
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




Procurement type E (in-house production): If you have maintained several PPMs for in-house production,
the system determines the PPM that has the highest priority. If several PPMs have the same priority, the system
uses the costs entered for each PPM to determine the particular PPM with the most appropriate costs. If the
system cannot use the cheapest production process model at the requirements date/time (for example, because
there is no available capacity at that date/time, and therefore there would be a deadline problem as the order
would have to be planned at a later date), the system chooses the next best alternative. If all the PPMs would
cause problems with the deadline, the system selects the PPM where the time of requirements coverage is
closest to the time of the requirement.
Procurement type F (external procurement:) During external procurement the system determines the
source of supply using the data maintained in the transportation lanes and in external procurement. It also uses
the priority and costs to select an alternative.
If the system cannot find a transportation lane/external procurement relationship, it generates a purchase
requisition without a vendor, and uses the planned delivery time from the product master record (GR/GI tab
page).
If both in-house production and external procurement are allowed (procurement type X), the APO system
selects the supply source with the highest priority. If several procurement options have the same priority, the
system uses the option with the cheapest costs. Here, the system directly compares the costs in the
transportation lane/external procurement relationship and in the PPM. If the costs are also the same, the system
triggers in-house production.
Procurement type P (external procurement planning): The product is not manufactured at the location, and
no orders are created for the product. As opposed to in-house production and external procurement, the
planning here does not take place in APO. Stock shortages are resolved mainly using the OLTP system.
Note: If you have specified quota arrangementsand entered a quota arrangement heuristic in the Heuristic
field on the PP/DS tab page in the product master, the system divides the requirement quantities according to
the defined quotas. The quota arrangement items are planned according to the heuristic deifned at quota
arrangement item level. The quota arrangement therefore has the highest priority.
© SAP AG
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
The availability check is controlled using several check instructions.

You define check instructions in Customizing for the individual application (for example, MRP,
Sales, Order Management, and so on).

Check instructions include various elements:
 Checking group - Assign in the material master record (MRP screen)
 Checking rule - Assign per plant/MRP group
 Scope of check - Define the inspection details per checking rule and group

Manual checking time selected according to line loading, for example.

Checking variants
 Manual check of the components of a planned order
 Collective availability check of several planned orders (mass processing)

Check results - Display backflushed quantity (partial quantities can be confirmed)

You can use the collective availability check to check whether the required components are
available for several planned orders simultaneously.
© SAP AG
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
A dynamic check of all receipt/issue elements is carried out.

Checking procedure: Calculation of the ATP quantities (ATP = available-to-promise)

Checking period: Total time axis, however, can be limited to the replenishment lead time (material
master record).

Using the ATP quantity, the MRP controller can determine whether all issues are covered by the
master plan and how much of the warehouse stock or master plan is still available for new issues.

Planned independent requirements are not included in the check. To check these, you can use the
availability check according to planned independent requirements.
© SAP AG
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Controlling the Availability Check - Material
R/3
Checking control - planned orders
Plant and
MRP group
Checking rule
 Assignment of a checking rule to an application (for example,
planned orders, sales order, production orders)
Checking group
 Assignment of a checking instruction to a material
A
Material
Scope of check
 Defining which elements to include in the check
(e.g. stock, firmed planned order, purchase orders...)
 SAP AG 2004

The availability check can be controlled depending on the combination of plant, MRP group, and
material.

The system includes in the check only those materials which contain a checking group (in the
material master record).

The scope of the check determines the elements to be included in the check (planned orders,
purchase requisitions, and so on).
© SAP AG
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Scrap Business Scenario
 Scrap may be produced when manufacturing
materials.
 Scrap resulting from technology should be planned in
your company so that at the end of the production
cycle, the required production quantity is available.
 Scrap that cannot be planned must be covered by
additional production and material.
 SAP AG 2004
© SAP AG
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Scrap Types and Effects
Assembly scrap
 Increases requirements quantity of all components
 Maintained in material master record of assembly
Component scrap
 Increases requirements quantity of one component
 Maintained in BOM or material master record for component
Operation scrap, net ind.
 Refines the scrap passed on the the components by
the assembly scrap
 Maintained in BOM
Production
orders
Operation scrap in routing
 Reduces operation quantity of subsequent operations
 Maintained in routing
Production
orders
 SAP AG 2004

You can plan for scrap in the master data (material master record, BOM, and routing). Planned scrap
is included in MRP, Repetitive Manufacturing, and Material Costing.

The different scrap types have different effects. Scrap in the material master record and in the BOM
increases the requirements of all or of one component(s). Scrap in the operation of the routing
reduces the operation lot size of subsequent operations (used for production orders):
 Assembly scrap: Assembly scrap is used in MRP for calculating the lot size of the assembly.
Here, the system increases the quantity to be produced by the scrap quantity calculated. For
example, the quantity to be produced is 100 pieces and you enter a scrap value of 10 %. This
means you expect a scrap quantity of 10 pieces. The actual quantity to be produced is then
calculated at 110 pieces.
The system increases the production quantity for all components of the assembly.
 Component scrap: Component scrap is calculated in MRP to determine the quantity of
components required for production. When exploding the BOM, the system increases the required
quantity of components by the scrap quantity calculated.
Example: Required quantity 100 pieces, component scrap 10% - that is 10 pieces. Required
component quantity is then 110 pieces. Backflushing note: When backflushing a yield of 10 pieces
for the assembly, the system posts a goods issue of 10 pieces but reduces the dependent
requirements from 110 pieces to 99 pieces (due to the scrap level maintained). If you backflush a
yield of 10 pieces for the assembly with adjusted goods issue of 10 pieces for the components, the
dependent requirements are still reduced from 110 to 99 pieces.
If assembly scrap occurs for a higher-level assembly, the system adds both scrap types. If you
have maintained component scrap in the BOM, the system uses the value specified here.
Otherwise, the system uses the value maintained in the material master record.
© SAP AG
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 Operation scrap: Scrap expected in an operation for the quantity of component to be processed. It
replaces the estimated assembly scrap for more valuable materials. When taking operation scrap
into account, the components of the subsequent operations are not overplanned in MRP. If you
create operation scrap, you also have to set the operation scrap net indicator (Net field).
 Only when processing production orders (not for repetitive manufacturing): Scrap in routing
operation: In this case, scrap quantity as a percentage. The scrap quantity that occurs in the
operation causes a quantity reduction in the next operation, since the processed quantity has been
reduced by the scrap quantity. The quantity reduction is taken into account in scheduling and in
costing.
© SAP AG
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Planning Line Loading in Simulative Mode:
Business Scenario
R/3
 In operative planning, you work with the planning
table in Repetitive Manufacturing.
 Now, you also want to use long-term planning to
simulate the planning for line loading.
 SAP AG 2004
© SAP AG
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
The principle of long-term planning is to simulate various version of the demand program. In the
simulation, you can take operative data into account (for example, master data, sales orders, purchase
orders, production orders). Using the simulation, you can optimize the demand program and the
procurement data with regard to MRP, capacity planning, order volume, purchasing budget, cost
center planning, and inventory controlling.

In long-term planning, you can setup your own "planning areas" which are integrated in your
operative planning. These planning areas are differentiated by separate simulation data with which
the scenarios are carried out. A separate simulative planning area exists in the system for every
scenario. You can also copy operative data to a simulative planning area or to several simulative
planning areas, or it can be referenced (taken into account) in the planning areas.

You can carry out simulative planning on a long or short-term basis. There are no time limitations
for carrying out long-term planning. Make sure that the planning areas of long-term planning and
operative planning are coordinated with each other to avoid any inconsistencies.
© SAP AG
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Line Loading in Simulative Mode in the Planning
Table
5.9.2001
Planning scenario 001
Capacity data
Un
Due
4.9.2001
Line 1
Requirement
Av. capacity
Line 2
Requirement
Av. capacity
%
hr
hr
%
hr
hr
0
0
16
0
0
16
100
16
16
0
0
16
Material data
Un
Due
Material A
Requirements
Available qty
pc
pc
200
Production line 1
Production line 2
Not yet assigned
pc
pc
pc
0
R/3
In this section, you can
monitor the simulative
capacity load utilization
on
50 the production lines.
8
16
150
24
16
5.9.2001
In this section, you can assign
4.9.2001 the quantities to the production
lines in simulative mode.
100
200
100
200
100
50
50
0
200
Assignment mode
 SAP AG 2004

If, in operative planning, you work with the planning table of Repetitive Manufacturing, you can also
use the planning table in long-term planning to carry out simulative planning in a planning scenario.

In long-term planning, the planning table uses the same settings as the operative planning table. All
you have to do is create a planning scenario and enter it in the initial screen of the planning table.

Scope of function:
•You can copy the planned orders from operative planning in order to process them in the
planning table.
•Once you are satisfied with your simulative planning results, you can copy them back to
operative planning.
•You can access the planning table in long-term planning from the long-term planning menu.

To display data from long-term planning for comparison in the operative planning table, enter the
number of the planning scenario in the initial screen of the operative planning table. Then the data
from long-term planning is displayed in the operative planning table in a separate row per material.
To make sure that the Comparison scenario field is displayed in the initial screen, you must select
the Long-Term Planning indicator in Customizing for the planning table, in work step Maintain Row
Selection.
© SAP AG
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Copying Firmed Planned Orders
Copying Firmed Operative Planned Orders to LongTerm Planning
Simulative
R/3
planning run
After
Simulative planning area
Simulative planning area
Copy
direction
*
*
*
*
*
Today
Today
Before
*
t
Operative planning area
t
Operative planning area
 SAP AG 2004

You can copy firmed planned orders from operative MRP to the simulative planning area. Only the
planned order headers are copied. Any changes to the components of the planned orders you made in
operative planning are not passed on to the simulative planning. In simulative planning, the planned
order components are recreated according to the selected BOM.

The firmed planned orders are copied for each material by the simulative planning run in the
simulative area. Here, for every material in a BOM structure, all firmed planned orders are selected
and copied (to the simulative area). These planned orders are also firmed in long-term planning.
However, they can be changed manually.

For each material, the order finish date of the planned order last to be selected and copied is saved as
the temporary end of the copying period. The copying period is determined by the operative, firmed
planned order that lies furthest in the future.

When copying a firmed planned order from operative planning, the system deletes all firmed and
non-firmed simulative planned orders whose order finish dates lie within the copying period.
© SAP AG
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Copying Firmed Planned Orders
R/3
Copying Firmed Simulative Planned Orders to
Operative Planning
Operative
individual
planning
interactive
After
Before
Simulative planning area
Simulative planning area
*
* * *
*
*
*
*
t
Copy
direction
*
* *
*
t
*
t
Operative planning area
Operative planning area
 SAP AG 2004

After the simulation, you can copy the firmed, simulative planned orders from the simulative
planning area back to operative planning. For material procured externally, you can create purchase
requisitions or schedule lines in the operative area.

You carry out this copying procedure for each material using the transaction Interactive, Single-Item
Planning in operative MRP. In the subsequent screen with the planning results, you trigger the copy
using the function Process - copy simulative planned orders. Here, you specifically define the start
and the end of the copying period.

All firmed planned orders whose order finish dates lie within the selected period are copied from the
simulative planning area to the operative planning area. In the operative planning area, all firmed and
non-firmed planned orders whose order finish dates lie in the copying period are deleted, so that only
the planned orders copied from the simulative area remain in operative planning in this period.
© SAP AG
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Planning Table: Planning Identification
R/3
 Planning ID as group criterion
 Planning ID for quantity planning
 SAP AG 2004

Definition: Using the planning ID, materials can be grouped for planning and evaluation.

Use:
• Planning ID as group criterion:
- The planning ID is used as a group criterion, which make it easier for you to find production
versions using evaluations.
- In the planning table, you can restrict your selection to production lines by entering a planning
ID. This is useful if you can produce several materials on one production line, but not all can be
processed at the same time. In this way, all materials that are produced in a specific packing size,
for example, are grouped using the planning ID.
- You can then group the materials and create a planning ID for each group.
- You then enter the planning ID in the production versions of the materials.
- If you select by production line in the planning table, and also enter the planning ID, only those
materials with the same planning ID are selected for processing.
• Planning identification for quantity planning (For examples see the SAP Online Documentation):
- In addition, planning IDs allow a simplified line-related quantity planning without capacity
planning, as totals for the planning ID can be displayed in the planning table. This can be of use if
you work with deviating units of measure.
- The production unit of measure would be "crate" for drinks for example, and the system should
determine the number of bottles.
- The prerequisite is that you create the planning ID with the same number as the production line.
You enter the conversion factor for the deviating unit of measure in the material master.
- You enter the planning table by choosing the production line. Then in the planning table the
production quantity totals are also shown for the deviating unit of measure.
© SAP AG
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QM in Repetitive Manufacturing: Business Scenario
 You are a manufacturer of personal computers and
use repetitive manufacturing techniques. Quality
inspections are carried out at regular intervals
throughout the production process.
 SAP AG 2004
© SAP AG
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
You have the option of integrating Repetitive Manufacturing with Quality Management (QM). You
are therefore also able to carry out the check parallel to Repetitive Manufacturing. Using the
inspection monitor (transaction MFPR), you can monitor and create inspection lots for the
production version. An inspection lot instructs a plant to carry out a quality inspection for a certain
material quantity. You enter the inspection results for an inspection lot in Quality Management. The
inspection results are stored in the inspection lot and form the basis for the usage decision.

Current inspection lots for a production version can be closed in usage decision and new inspection
lots, for example, with changed default data (e.g. changed tolerance values of characteristics) can be
created for this production version. This means that the inspection data can be updated when the
planned data is changed, without creating another production version. In this way you can introduce
changes to planning in the current inspections.

Prerequisites:
 Material master record finished product (Quality Management view): You need to set the indicator
for QM inspection data, and enter and activate inspection type 13 (check for run schedule header)
in the QM inspection data.
 In the routing for the finished product, you must maintain inspection characteristics for the
operation for which the inspection results are to be entered. When you leave the operation
overview, you branch to the Inspection Characteristics Overview. You must enter this routing in
the production version (in the area Detailed Planning or Rate-Based Planning). The system selects
the routing entered in Detailed Planning. If no entry has been maintained here, the system then
copies the routing from Rate-Based Planning.
© SAP AG
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QM in Repetitive Manufacturing: Inspection Lot
Monitor
Create
New
production version
for material 4713
Monitor
Create inspection lot
Material
Plant
Production version
Valid from:
Material short text
Valid to
4711
1
0001
09.24.
Tin type A
12.31.
4712
4713
1
0001
0001
Tin type B
Tin type C
4714
1
0001
03.19.
Tin type D
12.31..
2
04.06.
12.31.
QM active Insp. lot
Insp. lot no. VE
12000013
12000014
12000015
 SAP AG 2004
 A monitor (transaction MFPR) is available for monitoring and creating the inspection lots for the
production version.
 The use of traffic lights shows whether inspection lots exist for all production versions of a material,
or whether production versions without inspection lots exist for materials to be included in the
inspection.
© SAP AG
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© SAP AG
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Triggering Replenishment via WM (for Pick Parts)
Storage bin 1: Mat.A
(storage type 100)
Direct display of the
missing quantity
situation for each
storage bin (missing
quantities calculation:
order-based)
Storage bin 2:Mat.B
(storage type 100)
Issue supply area 1
Co
nt
ro
lc
Transfer order
irc
le
Pull list
Reqmts
Stock
Missing
parts
Replenishment
storage location
WM-managed
(e.g. central warehouse)
 SAP AG 2004

For pick parts, the system takes note of the quantity that has already been staged for each individual
requirement. If this quantity is smaller than the quantity required, a requirement-specific missing
parts quantity is identified. Component staging is therefore order-related. Replenishment is only
triggered for a concrete requirement. This pick parts procedure in the pull list can only be used for
repetitive manufacturing.
As with the release order parts procedure, transfer requirements or transfer orders can be created
directly in the pull list. A list of the replenishment elements can be printed, to be passed on to
warehouse personnel. Once the requirements have been staged, goods issue is confirmed by
warehouse personnel.

Prerequisites:
 A supply area must be maintained as the issue supply area in the BOM or material master.
 The storage location to which the supply area is assigned is managed by WM.
 A WM control cycle must be maintained with the material staging indicator 1 (pick part) for the
supply area. Pick part control cycles can be applied cross-material (that is, only when a supply
area is specified). All requirements for this production supply area are therefore staged as pick
parts - that is, as long as no other material-specific control cycle with a different material staging
indicator already exists.
 The WM pick parts provision type must be specified in the initial screen of the pull list. You then
access the pick parts view directly.
© SAP AG
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© SAP AG
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Planning and Backflushing in Multi-Plant Repetitive
Manufacturing
Production Line
Plant A
(Planning plant)
Goods issue components
Goods receipt
assembly
Receiving storage location
Issue storage location
Plant B
(Production plant)
 SAP AG 2004





Use: You can use multi-plant repetitive manufacturing if you want to carry out the planning and the
production of an assembly/finished product in different plants. From a business point of view, this
planning method is particularly useful if the planning plant and the production plan lie very close
together, as then transport costs from one plant to the other are not taken into account.
Planning in multiplant repetitive manufacturing: In the planning table, the system provides a
separate row for every planning plant which is different to the production plant. This means you can
process the planned orders of the different planning plants separately from one another and you can
also create new planned orders for one particular planning plant.
Backflushing in multiplant repetitive manufacturing: Once you have produced the assemblies, you
carry out the backflush for the planning plant. Here, the system posts the goods receipt of the
assembly in the planning plant and backflushes the components in the production plant. Then the
planned orders are credited and the production costs are updated to the product cost collector.
Activities: In the backflush, enter the planning plant in the Planning plant field. The production plant
for the components is automatically read via the special procurement key. If, however, you want to
post the goods issues from another plant, you must also enter this plant in the Plant field.
Prerequisites:
• Planning plant: You must create a material master record for the assembly containing a special
procurement key for production in another plant (production version not necessary).
• Production plant: You must create a material master record, a BOM, and a routing for the
assembly. In the material master record, maintain a production version containing the BOM and
the production line. You must also create a product cost collector by entering the planning plant
in the Planning plant field.
You can use multiplant repetitive manufacturing irrespective of whether you use make-to-stock
repetitive manufacturing, make-to-order repetitive manufacturing, or KANBAN with planned orders
in repetitive manufacturing.
© SAP AG
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
Handling units uniquely describe (number) a combination of goods and packing.

In Handling Unit Management, goods from a non-HU storage location are reposted to a HU storage
location. Therefore, Inventory Management is completely converted to HU - that is, the HU is the
Inventory Management object.

The packing transaction in repetitive manufacturing is HUP1 and can be found in the backflushing
menu under HU Management. The corresponding Customizing for HU Management (under General
Logistics - HU Management) addresses the definition of packaging material types (field in sales
view/general plant data), the material group definition (field in basic data 1 - view) and the
assignment of both definitions.

The packaging process is executed in 2 steps: First planning/simulation of the packing situation/stock
transfer and then when saving, the HU is created and activated - a material document is created.

A cascade (multiple packing) is possible - transaction HU02.

General transaction calls and further information on Handling Unit Management can be found in LO
? Central Functions ? Handling Unit Management
© SAP AG
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
In engineering/design, you can specify that one material is to be switched for another at a certain
point during production . Such changes may be necessary for the following reasons:
­ Different safety regulations apply after a certain time: A component that no longer corresponds
to the safety regulations must therefore be switched.
­ An expensive part is exchanged with a more reasonably priced one.

Simple discontinuation: A component in the process of being discontinued is replaced by a followup material from a certain date - that is, as soon as the available stock for the discontinued
components has reached zero.

During backflushing, the system monitors that the follow-up backflushing material only be chosen
when the discontinued stock is no longer available. This is done according to the warehouse stock
availability.
If, during backflushing, part of the goods issue quantity can be covered by the discontinued
component, the system posts two items: an item for the remainder of the discontinued component
and a further one for the open quantity of the follow-up material.

Prerequisites: You must set the discontinuation indicator 1 and enter a follow-up material in the
material master record for the discontinued components. If the discontinued parts should not come
into force until a certain date, then you must also maintain an effective-out date.
© SAP AG
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Discontinued Parts (Parallel Discontinuation)
R/3
BOM in discontinuation phase
- L03 (left wing mirror
model year 2003):
Car
Main part to be discontinued
- L03/R03: Discontinuation group
- L04/R04: Follow-up group
L03
R03
L04
R04
Initial situation
New BOM
Car
L04
R04
Available
stock L03 > 0
Available
stock L03 = 0
Plnd order
Car
Plnd order
Car
Plnd order
Car
Plnd order
Car
L03
L03
L04
L04
R03
R03
1.1.04
Effective-out date 01.01.2004
R04
R04
Time
Change BOM
 SAP AG 2004

Parallel discontinuation: A group of materials is replaced by another group of materials - that is,
when a component (main discontinuation item) is discontinued and its available stock has reached
zero, then another component (dependent discontinuation item) must also be discontinued. If, for
example, a left wing mirror is discontinued, then the dependent right wing mirror must also be
discontinued. Depending on the warehouse stock availability, the system controls which follow-up
material will be chosen for backflushing when the discontinuation material is no longer available. If,
during backflushing, part of the goods issue quantity can be covered by the discontinued component,
as with simple discontinuation, the system posts two items.

Prerequisites:
­ Material master record: In the material master record of the main discontinuation item, you
must set the discontinuation indicator 1, and in the material master record of the dependent
discontinuation item you must set the discontinuation indicator 3.
­ BOM: In the general data of the BOM item, you define the same discontinuation group for the
main as for the dependent discontinuation item. These freely definable character string group
associated, discontinued items together to one BOM. In addition, the follow-up group
determines which discontinued items are to be replaced by the follow-up items. You define the
follow-up group in the general data of the BOM item, which then groups together the associated
follow-up items of a BOM (following components). The character string of the discontinuation
group and the follow-up group must tally.
© SAP AG
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Alternative Parts Processing
R/3
 Withdrawal by usage probability (strategy 1):
Usage probability C: 40%
Usage probability D: 60%
A
GR for A: 100 pc. -> GI for C: 40 pc.
B
C
D
GI for D 60 pc.
GI for B: 100 pc.
Alternative item group 01
 Withdrawal at 100% availability (strategy 2)
Ranking order for C: 1
Ranking order for D: 2
A
B
C
D
Alternative item group 01
 SAP AG 2004

In engineering/design or shop floor control, you can define a components group which can be
assembled in various ways. This is the case, for example, when there is a group of substitute
materials for a certain material, from which each material can theoretically be assembled. Referring
to the available quantity, the system controls which components are chosen for backflushing. There
are two different withdrawal strategies:

Withdrawal by usage probability (strategy 1):
You can, for example, define three alternative items (components) with similar attributes. The first
alternative item is withdrawn at 50%, the second at 30% and the third at 20%.

Withdrawal when 100% available with priority (strategy 2):
You can, for example, define two alternative items (components) with similar attributes and specify
priorities in the BOM. The system first tries to withdraw the first alternative item, though should
there be less stock available than needs to be withdrawn, then the system takes the entire quantity
from the second alternative item. If this quantity is also insufficient, the system will generate a
backlog for the first alternative item. Using this strategy, you are not able to withdraw mixed
alternative items.

Prerequisites: In the General Data of the BOM items, you must have grouped all materials that
could be used differently in the production process to an alternative item group. If you create an
alternative item group, you must enter either priority or usage probability, depending on the strategy
you select. Sequence, usage probability.
© SAP AG
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Serial Number Procedure
Serial numbers
Production line
4711
4710
Material A
Material A
Receiving storage location
 Assignment at final backflush (automatic or
manual assignment)
 SAP AG 2004

Serializing a material enables you to trace objects individually. During backflushing, materials
requiring a serial number are assigned one. The combination of material number and serial number
is always unique. The serial numbers are contained in the material document. In the menu screen for
Repetitive Manufacturing, you have options for collectively creating, displaying, and changing serial
numbers.

Prerequisites:
­ You have flagged the material as requiring a serial number using the serial number profile
(Sales view) in the material master record.
­ You have specified in which way the serial numbers should be assigned. This is done in
Customizing for Sales and Distribution in the assigned serial number profile for the serialization
procedure PPSF (maintain run schedule header with serial numbers).
Automatic assignment means that the system automatically assigns the serial number
according to the settings in the serial number profile when the backflush is posted. During final
backflushing, when making the required entry you receive a dialog box saying Maintain Serial
Numbers and are required to assign a serial number there and then. The goods receipt cannot be
posted without a serial number. You can either enter a serial number manually or have the
system assign the next free serial number. For the latter scenario, enter Create SerialNo. Autom.
Repetitive Manufacturing does not support serial numbers entered as optional entries.

In Repetitive Manufacturing, you can only execute the serial number procedure for the assembly or
finished product, not for the components.
© SAP AG
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Collecting Costs in the Sales Order
Sales order
item
Material costs
Components
Debit
Production
activities
Debit
Overhead
Debit
SD
Sales
order
Balance
sheet
account MM
Sales order
stock (valuated)
$20 000
$5 000
$1 500
Sales order
item
Material costs
Components
Debit
Production
activities
Debit
Overhead
Debit
$10 000
SD
Sales
order
MM
Sales order
stock (valuated)
$5 000
$1 500
 SAP AG 2004

Collecting costs in the sales order (with non-valuated sales order stock):
Costs are not collected or settled via a production cost collector. The quantity flow (goods receipt,
goods issue) takes place via sales order stock, while the value flow takes place via the sales order
item (finished materials are delivered to sales order stock without being valuated). Materials
management, therefore, manages the quantities per material and per sales order item. In
backflushing, costs are assigned to the appropriate sales order item. If you are working with nonvaluated sales order stock, in order to determine the inventory values of the finished and nonfinished products you must carry out a results analysis at period-end closing. Work in process is not
posted in Financial Accounting until the sales order is settled.

You can use cost collection via the sales order instead of cost collection via a product cost collector.
In make-to-order repetitive manufacturing, you generally collect costs using the product cost
collector rather than using the sales order method - especially when working with very large numbers
of orders.
© SAP AG
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Period-End Closing: Sales Order Item (NonValuated Sales Order Stock)
SalesOrder
1. Process cost allocation
2. Recalculation of act. prices
SD
3. Surcharges
4. Results analysis
5. Variance costing
6. Settlement
 SAP AG 2004

In the CO period-end closing for the sales order item, you can:
1. Carry out process cost allocation.
2. Revaluate activities that were debited with cost objects, according to the actual activity price.
3. Carry out the overhead calculation.
4. Carry out a results analysis to determine, for example, work in process.
5. Variance costing is not usually possible for sales order items,
6. Carry out the settlement:
If you are working with non-valuated sales order stock, in order to determine the inventory values
of the finished and non-finished products you must carry out a results analysis at period-end
closing. Work in process is not posted in financial accounting until the sales order is settled.
© SAP AG
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
Takt-based flow manufacturing represents a system-specific mapping of contents in the repetitive
manufacturing area, for which the "takt" is highly important. Because in most cases this process is
seen in the automotive industry and its suppliers, only the basic functions are available in the R/3
standard system. These functions are covered in this material. There are more functions available in
the mySAP Automotive industry solution.
© SAP AG
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
The facts and information you have covered during the units concerning material staging, backflush,
and evaluations are all equally valid for takt-based flow manufacturing.

There are differences in the master data and the planning contents for takt-based flow manufacturing.
These are outlined in the following material.
© SAP AG
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Takt-Based Flow Manufacturing
(Takt-Based Production)
Materials/planned orders
Cycle
Planned takt time (how often material placed on line)
Takt-based scheduling and Sequencing
Maximum takt
time (line
speed)
Production Line
 Takt-based scheduling: Planned orders for all materials are dispatched to the
production line based on a common takt time with start and end dates under a
day - the takt time is determined previously
 Sequencing: Planned orders are scheduled in a favorable sequence
 Planned orders (run schedule quantities) authorize production
 SAP AG 2004

In takt-based flow manufacturing, takt-based scheduling and sequencing for the planned orders
usually take place simultaneously:
• Takt-based scheduling: In takt-based scheduling in sequencing, every material/planned order
is dispatched to the production line using the same takt time/production rate.
• Sequencing: The individual planned orders can have quite different runtimes due to different
configurations, for example. Therefore, the planned orders have to be dispatched to the
production line and produced in an optimal order sequence.
Using the optimal determination of the planned order sequence, you can avoid a situation where
several long planned orders are produced in sequence on the production line. Such a sequence
would certainly lead to a capacity overload of the production line.
This means the combination of line balancing of the takt-based scheduling and sequencing
planning replaces the more traditional capacity planning.

Planned orders authorize production in takt-based flow manufacturing. Production orders are not
necessary (no conversion).
© SAP AG
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© SAP AG
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Master Data for Takt-Based Flow Mfg: Contents
 Creating a line hierarchy
 Dividing the production process
into operations
 Line balancing a production line
 SAP AG 2004
© SAP AG
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Overview of the Logistics Master Data
for Takt-Based Flow Manufacturing
 Repetitive manufacturing indicator and profile
 Production version(s)
Material master
 Planned material consumption
 Storage location for backflush
BOM
Production line
Routing
Routing
 SAP AG 2004

In the material master record and in the BOM, you have to maintain the same master data as if you
were working with classic Repetitive Manufacturing based on quantities and periods.
© SAP AG
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Overview Master Data: Production Line
 Repetitive manufacturing indicator and profile
 Production version(s)
Material master
 Planned material consumption
 Storage location for backflush
BOM
 Production line as a line hierarchy
Production line
Routing
Routing
 SAP AG 2004

For takt-based flow manufacturing, the production lines are represented as line hierarchies, since you
can only maintain takt times for a line hierarchy.
© SAP AG
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Line Hierarchy
am-line1
Line hierarchy
Feeder line
am-400
am-300
am-310
Takt 1
Takt 2
am-310
am-320
am-410
am-420
Takt as subdivision
of a work center
Feeder line
 SAP AG 2004

Use: Complex production lines which have more than one work center can be represented in a line
hierarchy. A line hierarchy can be subdivided into as many line segments (work centers) as
necessary. You can subdivide the line hierarchy over 99 levels.
The line segments on the lowest level of the hierarchy are those where work actually occurs, whereas
the work centers on the upper levels are used only for grouping purposes.

Prerequisites:
• The individual line segments are created as work centers in the R/3 System. You can organize
the work centers using various work center categories (for example, zone, station, and so on). It
makes sense to do this, for example, on the various levels of the line hierarchy.
• The individual work centers are grouped to a line hierarchy via a graphic in the Line Design
menu. The production line displayed by the line hierarchy takes its name from the uppermost
work center.
• If you do not want to create an individual work center for every processing station in the
production line, you can divide a work center into individual takts in the line hierarchy graphic
(in takt-based scheduling, a material remains in a line segment for the number of takts
multiplied by the takt time. However, if you want to work with lead time scheduling via the rate
routing, the system does not take the number of takts per work center into account when
calculating the duration of the operations).
• Line segments which represent feeder lines to the main line are defined as feeder lines in the
line hierarchy graphic (and are displayed as a broken line).
© SAP AG
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Changing the Sequencing After Sort Buffer
Visualization segments
am-line1
First-in, firstout (FIFO)
am-200
am-210
Line hierarchy
am-220
Manual
planning
am-400
Sort buffer 1
am-410
am-420
Processing
profile
Line segment
am-200
am-400
14 3
5
4
7
8
1
2 18
4
2 14 1
3
5
7
8 18
Time
 SAP AG 2004

Use: Sort buffers are buffers in which the sequence of the planned orders can change (for example,
before the paint shop so that the same color of materials can be painted in sequence).

If you insert a sort buffer into the line hierarchy, you split the production line into several partial
lines. You can maintain a processing profile for each partial line that the system uses in takt-based
scheduling to determine the sequence of the planned order (e.g. external procedure).

Activities: You can define different operating times for the partial lines between sort buffers. If you
insert buffers in the line hierarchy, the system determines the operating time from the first line
segment and the line segments immediately after a sort buffer.

Scheduling and visualization: When you have split the production line into partial lines using sort
buffers, the system creates a schedule record for the planned orders for each partial line in
sequencing. You can define a line segment of a partial line as the visualization segment for planning
meaning that the system then displays the dates of this partial line in the sequence schedule.

Prerequisites: You must create a line segment that lies in the first hierarchy level below the header
of the line hierarchy between two line segments. Select this line segment and choose Line Segment
 Buffer  Sort buffer  Define. The system indicates that the line segment is a sort buffer and
represents this with a color.
© SAP AG
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Overview Master Data: Routing
 Repetitive manufacturing indicator and profile
 Production version(s)
Material master
 Planned material consumption
 Storage location for backflush
BOM
 Production line as a line hierarchy
Production line
Routing
Routing
 Standard routing or rate routing
 Operation or subdivision of the production
process into work operations for line balancing
 Standard values for operations
 SAP AG 2004
© SAP AG
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Representation of Feeder Lines in the Routing
Operations
10
20
30
40
50
am-110
am-120
am-130
am-140
am-150
10
20
am-210
am-220
Parallel
sequence 2
10
20
am-310
am-320
Parallel
sequence 3
10
20
am-510
am-520
Main
sequence 0
Parallel
sequence 1
Routing Material A
Work
center
Sequence 1
20
10
Feeder line
Sequence 0
20
10
30
40
50
Sequence 2
10
20
Sequence 3
10
20
underlined: longest path
 SAP AG 2004

Use: You can use feeder lines to represent operations that run parallel to the main line. The aim of
feeder lines is to shorten the total run time. You can also create parallel feeder lines for feeder lines.

Prerequisites:
• Create feeder lines as parallel sequences in the routing. The parallel sequences then contain the
operations of a feeder production line.
• In the return operation in the routing, you define the point at which the feeder production line
meets the main production line. If you have a parallel production line that is joined to the main
production line at both the start and the finish, you also enter a branch operation when creating
the parallel sequence. The branch operation is the one before which the operation sequence on
the parallel production line starts.
• The feeder production line must also be defined in the line hierarchy.

In the operation/sequence graphic in the rate routing, you can display the longest path. This shows
the operations that must be considered in order to achieve a further reduction in lead times.
© SAP AG
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Motivation: Line Balancing a Line Hierarchy
Assigned materials
Mat. A
Mat. B
am-200
Line hierarchy
am-line1
am-300
Line segment
am-310
10
(3 Min.)
20
(3 Min.)
Operations from
routing
am-320
30
(2 Min.)
Takt time (for example, 5 minutes)
Aim of line balancing: Optimum loading of operations to the line segments
Result of line balancing: Routing that can be carried out.
 SAP AG 2004

Use: In takt-based production, the same takt time is available for carrying out the operations in
every processing station of a production line.
Therefore, you have to make sure that the routing is set up so that all operations assigned to one
processing station in the routing, can be carried out within the defined takt time.
For this purpose, the line balancing function is available which you can use to determine whether
the routing's operations at the individual processing stations can be executed with the defined takt
time.
The aim of line balancing is to assign each processing station the optimum number of operations.
The total of the operation times should be as close as possible to the takt time.
© SAP AG
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Maximum, Planned, and Operative Rate/Takt Time
in Line Balancing
Operative rate/takt time
overrides planned
rate/takt time for certain
period (e.g. shift)
Materials
Planned rate/takt time as
line-on speed
Maximum rate/takt time
as line speed
Various takt times affect later scheduling
Low line-on speed
High line-on speed
 SAP AG 2004

In line hierarchy or in line balancing, you enter the production rate. The system uses this rate to
calculate the corresponding takt time, which is the reciprocal value of the rate.
 Definition: Line design distinguishes between the three following rates/takt times per production
line (for all materials on a production line), which are used for takt-based scheduling in sequencing:
­ The maximum production rate/takt time defines the line speed of a production line. It
therefore defines the time available for processing a material in a processing station (takt)
before reaching the next processing station.
This means, you use the maximum rate/takt time to determine the maximum quantity output of
a production line on a long-term basis.
­ The planned production rate/takt time defines the time interval in which, on the one hand, a
material is added to the production line and, on the other, a processed material leaves the
production line. Therefore, it defines the time which passes on the production line between the
completion of two quantity units of a product. You use the planned rate to plan the production
rate for a period on a short to medium-term basis. You can determine the planned rate manually
or you can use line balancing to calculate it automatically.
­ The operative production rate/takt time overrides the planned production rate. You can use
this value to react to requirement or capacity changes in the very short term. For example, you
can define the operative rate for a shift.
 If you only enter a maximum production rate, the maximum, the planned, and the operative
production rates/takt times are identical.
 The rates/takt times are valid for all processing stations of a production line. Exception: If at one
point in time, you always only produce one material on a production line, you can also use materialdependent production rates, if necessary. Prerequisite: You must create the line hierarchy without
line balancing (this usually occurs if you only use the takt times/rates with the planning table, see
the unit Planning Takt-Based Flow Manufacturing).
© SAP AG
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Creating the Line Balance and Manually Entering
the Planned Rate (Production Rate)
Status 2 Inactive
Line balancing for line hierarchy: am-line1
Version 1
Valid from 01.01.2003 To 31.01.2003
Unit of measure: Piece
Time unit: Hour
Materials
Rate Prop. % Task list grp Group counter
Mat. A
50000001
144
75
1
Mat. B
50000001
48
25
1
Planned rate
Number
HH MM SS
5
Piece 16 Hour
192
Takt
Model Mix:
time
Receipts/reqmts
 SAP AG 2004

When creating the line balancing for a line hierarchy, all materials produced on this line hierarchy
are read according to the production version. The system also selects the routings from the
production version for these materials.
If not all selected materials are relevant for the line balancing, you can deleted the irrelevant
materials from the line balancing, or you can also include new materials as necessary. This means
you can select material that are "critical" to the line balancing and carry out the line balancing on the
basis of these critical materials.
Or, when creating a line balancing, you can copy the materials and routings from an existing line
balancing.

The planned rate/takt time of the line hierarchy is the total of the planned rates/takt times for the
individual materials. In the line balancing, this can be determined as follows:
• By manually entering the rate per material.
• By calculation using the function Determine Receipts/Requirements (see next slide).

The planned rates may be different in different periods, you can create as many line balancing
versions as necessary, each with defined periods of validity.

If you assign the status Inactive to a line balancing version, you can create several line balancing
versions with the same period of validity for simulation purposes. If you want to use the planned rate
of the line balancing for sequencing, set the status to Active.
© SAP AG
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
The function Determine Receipts/Requirements is available for calculating the planned rate: The
system displays a dialog box, showing the maximum and the average daily quantities of
requirements and receipts (on the basis of a specific selection period). Here, the system takes all
requirements and receipts into account that are also displayed in the MRP list. By copying the
column, you can transfer the average daily requirements quantities for the individual materials to the
Rate column, for example. You can then transfer these daily rates from the dialog box to the line
balancing by choosing Copy (if, however, the time unit of the line hierarchy is not day, but hours, for
example, you must make the entry 16 in the line balancing in the Number of time units if the line
hierarchy is in operation 16 hours per day).

Note on line balancing: When saving the line balancing, the routing in the line balancing (or
routings) is changed according to the change in the graphic line balancing (see next slide). You can
make the change with or without a change number:
• Without a change number: Every new version of a line balancing overwrites the existing
routing. Therefore, you can copy the existing routing and enter the copy in the line balancing
before saving the line balancing. This means you only change the copied routing. This
procedure without change number is particularly useful if you use the line balancing function in
medium to longer intervals.
• With a change number: You separate the various line balancings of a routing using changes
numbers. This means you only have to save one routing in the system. If you enter a new
version of a line balancing with a change number, the new line balancing version is based on
the status of the previous version. The line balancing with a change number is particularly
useful if you create line balancings in short, regular intervals.
© SAP AG
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Branching to the Graphic Line Balancing
Line balancing for line hierarchy: am-line1 (Version: 1)
Takt time: 5 mins
am-310
am-320
am-310
Expand
Mat. A
10
Mat. B
10
am-320
Model mix:
Mat. A: 75 %
Mat. B: 25 %
am-310
10
Average acc.
to Model mix
20
You change the
rate routing by
displacement
when saving the
line balancing
Time
Work center
Time
Average operation time
according to model mix
Operation
 SAP AG 2004

Use: You can use the graphical line balancing function to check whether the operations can actually
be carried out within the takt time in the individual takt areas on the production line.

The line balance displays the work content (total operations) per processing station as an average
value. The system calculates this average value from the average routing standard values for the
individual products that are produced on the production line. You enter a model mix to see which
products are produced in what proportions. As well as the average value, you can display the
operations per processing station for each product. The takt time is also displayed, so that you can
monitor whether the operations can actually be carried out within the takt time of the production line.

The aim of line balancing is to assign each processing station (takt) the optimum number of
operations. The total of the operation times should be as close as possible to the takt time.
• To do this, you can also move operations to other processing stations. Here, the system
automatically changes the routings used in the line balancing and renumbers the operations.
• You can also change the number of takts and the number of individual capacities of a line
segment you defined in the line hierarchy. Changes to the number of takts/individual capacities
are only valid for the respective version of line balancing. This means you can adjust the
capacity of the production line, which you created for a maximum load in the line hierarchy, for
every version of line balancing or for every period. You can transfer the number of takts and the
individual capacities from line balancing to the line hierarchy by selecting the Maximum Line
Balance indicator in the line balance.

The line balancing function displays all line segments at the lowest level of a line hierarchy. It also
displays line segments from higher levels, if these have been assigned operations.
© SAP AG
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Line Balancing for Configurable Materials
on the Basis of Material Variants
Super
routing
Material
master
Super
BOM
Configurable material
Link
Takt time: 5
mins
Critical material
variant A
Material
master A
Engine: 90 KW
Value
assignment
Critical material
variant B
Line balancing
Value
assignment
am-310
Average
Mat. A
10
Mat. B
10
20
am-320
Time
Material
master B
Engine: 120 KW
 SAP AG 2004
© SAP AG
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Master Data for Takt-Based Flow Mfg: Summary
 Line hierarchy
 Dividing the production process into operations
 Line balancing: For example, by moving
operations to other line segments of the line
hierarchy
 SAP AG 2004
© SAP AG
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© SAP AG
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Planning Takt-Based Flow Manufacturing in R/3:
Contents
 Takt-based scheduling in takt-based flow manufacturing
 Takt-based flow manufacturing with direct use of the graphic
sequence schedule especially for make-to-order production
(often high order volume, small lot sizes)
 Takt-based flow manufacturing with direct use of the planning
table (graphic sequence schedule here only for visualization
purposes)especially for make-to-stock production (often
small order volume, larger lot sizes)
 SAP AG 2004
© SAP AG
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
Make-to-stock production: You can use repetitive/flow manufacturing for pure make-to-stock
production. This means you produce products with no direct reference to sales orders. The planned
independent requirements from Demand Management are used as the basis for planning. Depending
on your production strategy, the planned independent requirements from Demand Management can
be consumed by sales orders.
The same product is produced repeatedly over a substantial period of time. The product is not
produced in lots. Instead, a total quantity is produced in a certain period at a certain rate. Products
pass through production in a relatively steady flow.
Sales orders are delivered from stock.

Make-to-order production (sales order-based production) You can use repetitive/flow
manufacturing for pure make-to-order production. This means you produce products with direct
reference to sales orders. The products are stored in the individual customer stock. Sales orders can
be processed separately. A planned order is created with direct reference to the sales order.
Production is therefore controlled using sales orders. The quantities produced cannot be swapped
between the individual sales orders. The produced quantities are stored specifically for the individual
sales order (individual customer stock) and not in the anonymous warehouse stock. If you use variant
configuration, you can plan and manufacture configurable materials using make-to-order repetitive
manufacturing.
Sales orders are delivered from individual customer stock.

Prerequisite: You use the strategy group in the material master record to control whether you want
to use make-to-stock or make-to-order repetitive manufacturing.
© SAP AG
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
Make-to-order production: A product can be configured according to customer requirements when a
sales order is entered (if the product is configurable). When you save the sales order, the product
appears in the stock requirements list in an individual planning segment.
The next MRP run creates a planned order for the sales order, whose component list contains only
the components that correspond to the customer's requirements.
The assignment of the planned orders to the production lines can already have been carried out
automatically in MRP. This can be carried out via quota arrangement (MRP menu) if a material is
to be assigned to several production lines. If the material is only to be assigned to one production
line, you can accomplish the automatic assignment using the alternative selection indicator = 2
(material master record).

The scheduling of the planned orders (and thus the exact time that the planned order is dispatched
to the production line) can be carried out in two different procedures:
• You can carry out scheduling in the planning table using the takt time/production rate of the line
hierarchy (takt-based scheduling in the planning table).
• You can carry out scheduling directly in the graphic sequence schedule (without the use of the
planning table) using the takt-time/production rate of the line hierarchy (takt-based scheduling
in the graphic sequence schedule). The planned orders can be dispatched in a specific order
sequence.

If you use assembly processing within make-to-order production, a procurement element (planned
order, production order, or network) is created automatically when you enter a sales order. Using this
procedure,you can also perform an availability check at component level when you enter the sales
order, since the finished product is not usually a stock item.
© SAP AG
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Multi-Application Functional Process
Material forecast
Plnd indep. reqmts
Sales/distribution
Demand program
Sales reqmts
B
A C D
E
MRP
Planned order
Run schedule quantity
Purchase requisition
Confirmation with
warehouse receipt
and backflush
Purchase order
Costing
Capacity planning
Stock
Goods receipt
Invoice receipt
Goods issue
 SAP AG 2004

Planning in Repetitive Manufacturing is a central part of a comprehensive process chain that
starts when you enter independent requirements (either planned independent requirements or
customer requirements) and ends with the goods issue of finished products.

In the SAP System, takt-based flow manufacturing can be used for the complete process for inhouse production of products only.
© SAP AG
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
The following objects/tasks lie within Tanja's area of responsibility: Dispatching, sequencing, sales
order/planner order management, capacity load, monitoring scheduling, forecast (extra single role),
sales clerk (extra single role).

She requires display authorization for the following master data: Production versions, line design
(work centers, rate routings, line balancing, operational method sheet), material master, material
BOMs, production resources and tolls, serial number maintenance, documents, supply areas, product
cost collectors, preliminary costing for the product cost collector.

She requires a change authorization for the following planning transactions: Planning table,
sequencing, collective availability check, stock/requirements list, pegged requirements, stock
overview, production list.

She requires authorization for the following evaluations(Production): Reporting point overview,
backflushing document overview, total requirements, reporting point statistics, goods receipts
statistics, component consumption, KANBAN info system, KANBAN error display, KANBAN
plant overview, control cycles/kanbans.

She requires authorization for the following evaluations (Inventory Management): Material
documents, posting and reversal documents and archived documents for the material, stock
overview, warehouse stock, provision stocks and so on, availability overview, plant overview, and
purchase orders.

She requires authorization for the following evaluations (Controlling): Variance analysis, work in
process, planned costs, actual costs, target/actual comparison (variance categories), production
version: line items actual/variance.
© SAP AG
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
Use: You usually use takt-based scheduling in make-to-order repetitive manufacturing if you
produce a large number of planned orders with small lot sizes to order (for example, production is
often executed with the lot size 1 in the automotive or computer industries). The use of lead time
scheduling for scheduling a large number of planned orders can lead to poor performance levels,
especially as you usually work with complex routings in make-to-order repetitive manufacturing.

Takt-based scheduling: Use the Sequencing transaction for scheduling. This means that the planned
orders are scheduled using the takt time/rate of the line hierarchy. In other words, the runtime of the
planned order is calculated according to the takt time/rate in the line hierarchy (and not using the
individual operation times from the routing!). In this case, every material is produced with the same
takt time/production rate. This means you can schedule, dispatch, and visualize a large volume of
orders.

Prerequisites:
• You must create a line hierarchy for the production line in line design. You must enter this line
hierarchy in the material master record in the production version.
• You must define the maximum production rate (as line speed) in the line hierarchy.
• You must enter the indicator Takt Time/Production Rate Scheduling in Customizing for
Repetitive Manufacturing in work step Define Scheduling Parameters for Planned Orders.
• You have already created planned orders (e.g. in MRP) which only have to contain basic dates.
The planned orders must already be assigned to the production lines before you access the
graphic sequence schedule (the production version must already be recorded in the planned
orders). This can be carried out using a quota arrangement (MRP menu) if a material is to be
assigned to several production lines. If the material is only to be assigned to one production
line, you can accomplish the automatic assignment using the alternative selection indicator =
2 (material master record).
© SAP AG
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Takt-Based Scheduling and Order Sequencing in
Sequencing
Planned orders for 02.01.2003
(Planning period: 1 day)
Start sequence
schedule
Planned rate/takt time
as line-on speed
Maximum
rate/takt time as
line speed
New planned order sequence
 SAP AG 2004

In make-to-order repetitive manufacturing, you use sequencing to execute takt-based scheduling and
to sequence the planned orders.
• Takt-based scheduling: In takt-based scheduling in sequencing, every material/planned order
is dispatched to the production line using the same takt time/production rate.
• Sequence planning: In make-to-order repetitive manufacturing, the individual planned orders
can have quite different runtimes due to different configurations, for example. Therefore, the
planned orders have to be dispatched to the production line and produced in an optimal order
sequence.
Using the optimal determination of the planned order sequence, you can avoid a situation where
several long planned orders are produced in sequence on the production line. Such a sequence
would certainly lead to a capacity overload of the production line.
This means the combination of line balancing of the production line and sequencing replaces
the more traditional capacity planning!

Several planning procedures are available for sequence planning in Sequencing. Sequence planning
is carried out per planning period (for example 1 day or 7 days).

Feeder lines are not scheduled in takt-based scheduling in Sequencing.
© SAP AG
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Takt-Based Scheduling: Example
Line
Planned rate: 12 pc/h
(Takt time: 5 mins)
1
2
Line hierarchy
(Number of takts: 3)
3
Production Line
Line
segment
5 mins
A
1
A
B
3
A
06:00
Scheduling of planned order A
Lot size
1 pieces
Production start:
06:00
Production end:
06:15
Execution time:
15 mins)
B
2
06:05
06:10
Maximum rate: 12 pc /
hr minumum takt time:
5 mins)
B
06:15 06:20 Time
Scheduling: Planned order B
1 pieces
Lot size
06:05
Production start:
06:20
Production end:
15 mins)
Execution time:
5 mins
 SAP AG 2004

Takt-based scheduling: This example shows the scheduling of two planned orders with lot size 1
(planned order A and planned order B). The planned rate/takt time of the current period in this
example corresponds to the maximum rate/takt time as this is often the case in make-to-order
repetitive manufacturing.

Number of takts: The production line consists of three line segments, each with one takt (line
segments 1, 2 and 3). This means every product must flow through 3 takts.

Maximum rate/takt time: A maximum rate of 12 pieces per hour has been defined for the line
hierarchy. This corresponds to a takt time of 5 minutes. The takt time is the length of time that a
material is processed in one takt (also line speed).

Planned rate/takt time of the current period: The planned rate defined for the current period in
line balancing corresponds to the maximum rate of 12 pieces per hour. This means that the line-on
speed in line segment 1 is every 5 minutes (that is, every 5 minutes a material is placed on the
production line at the line segment 1).

Scheduling: The system dispatches planned orders to the earliest possible point and calculates the
start and finish times on the work centers of the production lines. If a product goes through several
line segments (for example, processing stations) of a line hierarchy, the system calculates the
production start time on the first station and the production finish time on the last station.
Here, the system uses the following formula to calculate the execution time for the planned order:
(Number of takts - 1) * minimum takt time + planned takt time + planned order quantity

The maximum rate represents the line speed. As opposed to the planned rate (line-on speed), this
cannot be maintained dependent on time (which is often necessary). If you choose the indicator
Basis for takt-based scheduling when maintaining the line hierarchy, the system uses the planned
rate which can be maintained dependent on time as well as the line-on speed and the line speed for
scheduling. Restriction: The line-on speed is identical to the line speed.
© SAP AG
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Sequence Planning Methods in the Sequence
Schedule
Transmit
Optimization:
External system
assigns
sequence numbers
PP POI
Interface
Receive
Sequence per planning period and line
Optimization procedure
is customer-specific
Sequence planning alternatively using:
 First-in, first-out (FIFO)
 External system
 Manual planning
 SAP APO
 Customer exit
 SAP AG 2004

Sequence planning: In sequencing, the following planning procedures are available for
sequencing (definition and allocation per plant in Customizing in Repetitive Manufacturing in
Planning section in the work step Sequencing):
• If you work with external programs, then these determine the sequence of the planned orders.
Planned orders can be transferred via a standard interface (POI) from the R/3 system to an
external optimizing program. This determines a sequence on the basis of a customer-specific
algorithm. The external program records the determined sequence to the individual planned
orders as a sequence number. The planned orders are then transferred back into the R/3 System
and dispatched by Sequencing according to the sequence numbers.
When you access the sequence schedule the system immediately dispatches the planned orders
per planning period in the Sequence Schedule section of the screen, according to the sequence
numbers.
• In the first-in-first-out (FIFO) procedure, the system first plans all planned orders for maketo-order repetitive manufacturing according to the sales order number and the sales order item.
Then it plans the planned orders for make-to-stock repetitive manufacturing according to the
planned order numbers. In this procedure, therefore, the time you create a sales order or a
planned order determines the sequence.
• If you dispatch manually, all planned orders whose start date lies within a planning period are
dispatched to this planning period. You can then select planned orders in the Orders Not Yet
Dispatched section of the screen, and dispatch them manually to the sequence schedule using
Drag&Drop.
• User exit: You can use a user exit to connect to a self-defined planning procedure.
© SAP AG
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Graphic Sequence Schedule
Disp./reallocate
Line
Time
Deallocate
12.08.
15
30 45
Reschedule
Planning duration: 1 day
Sequence
schedule 12.09.
00 15 30 45
15
30 45
00 15 30 45
12.10.
15
30 45
Am-line1 08:00:00
10:00:00
12:00:00
14:00:00
Legend
Legend
Visualization
Visualization
16:00:00
18:00:00
No check
20:00:00
Am-line2 00:00:00
Available
02:00:00
Line
Row
Am-line1
Orders not yet dispatched
12.08.
12.09.
Partially
available
Not available
10.12.
1
2
 SAP AG 2004
 Use: In make-to-order repetitive manufacturing, takt-based scheduling and sequencing is usually carried out by
accessing the graphic sequence schedule. When accessing the sequence schedule, the system plans the planned
orders that lie in the period of examination (field Period of Examination in the initial screen) per planned
period as early as possible according to the planning procedure defined. The system executes sequencing every
time you access the transaction Sequencing. In make-to-order repetitive manufacturing, the graphic sequence
schedule is not usually accessed from the planning table with the sequencing option, but directly via the
Sequencing transaction.
 The result of sequencing is in make-to-order repetitive manufacturing visualized in the graphic sequence
schedule as follows:
• In order to display as many planned orders as possible simultaneously on the screen, the time axis is
folded in the sequence visualization.
• In the sequence schedule, the work-free time (e.g. breaks) of the production line is displayed in a gray
shaded area so that it can be easily distinguished from the operating time (lighter shading). Here, the
standard system uses the scheduling-relevant capacity in the work center of the header of the line
hierarchy.
• The planned orders can be displayed using different colors to represent different criteria. A full range of
visualization profiles are provided for this purpose. For example, the visualization profile MATV to
visualize component availability. This displays whether the components of the planned order are all
available, partially available or are not available (you can trigger the mass availability check with the
collective availability check from the Repetitive Manufacturing menu). You can also display up to three
characteristics per planned order graphically. A planned order bar can also contain three graphic elements
(large triangle, small triangle, and a symbol) to which you can assign a color depending on the
characteristic value (value, status). This means, for example, that you can display the configuration of the
planned order graphically.
You can create the visualization profile in Customizing for Repetitive Manufacturing in the work step
Sequencing. In the graphic sequence schedule, you can specify a visualization profile as a user-specific
setting.
© SAP AG
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Sequence Schedule: Control View
Date of examination
Date earlier/later
Sequence schedule: View of line - 22.01. 10:00:00
Line
Orders still to be produced
Completed orders
am-210
Am-line1
am-220
Sort buffer
am-410
am-420
Am-line2
 SAP AG 2004

Use: You can use the control view to see exactly where the dispatched planned orders are situated on
the production line at a specific point in time. The control view displays the complete production
line, including the sort buffers, in a column of the sequence schedule. The production line is split
into the visualization segments for control that you can define in the line hierarchy. In each
visualization segment, the sequence schedule displays the order bars which are currently being
processed in that particular segment.
In the control view, the system also displays a queue of the orders still to be produced before the
production line and the completed orders after the production line.
© SAP AG
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Use of the Planning Table in Takt-Based Flow Mfg
Course Objectives
At the end of this unit, you will be able to:
 Use takt-based flow manufacturing with direct usage
of the planning table (graphic sequence schedule here
only for visualization purposes)
 Use this process especially for make-to-stock
production (often low order volume, larger lot sizes)
 SAP AG 2004
© SAP AG
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
Takt-based scheduling: If you access the planning table using the Sequencing selection, the system
schedules the planned orders in the planning table using the takt time/production rate from the line
hierarchy (that is, the execution time of the planned order is calculated using a combination of the
takt time/rate, the planned order quantity and the number of processing stations). The load of the
production line is calculated by comparing the occupied time (planned order quantity combined with
takt time and number of processing stations) with the available capacity of the production line
(standard available capacity or shift program).

Use: Takt-based scheduling has the advantage that you do not have to maintain the routing.
However, in this case, every material on the production line is produced with the same takt
time/production rate of the line hierarchy. Exception: If at one point in time, you always only
produce one material only on a given production line, you also have the option of using Sequencing
with material-dependent production rates. Then in line design, you can only specify materialdependent rates if you work with a line hierarchy without line balancing (this is usually the case if
you only use the takt times/rates in the planning table). Sequencing takes these rates into account if
you override the planned production rate for the material in question.

Prerequisites:
• You must create a line hierarchy for the production line in line design. You must enter this line
hierarchy in the material master record in the production version.
• You must define the maximum production rate (as line speed) in the line hierarchy. The
system uses the rate to calculate the corresponding takt time, which is the reciprocal value of
the rate.
• You must enter the indicator Takt Time/Production Rate Scheduling in Customizing for
Repetitive Manufacturing in work step Define Scheduling Parameters for Planned Orders.
© SAP AG
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Takt-Based Scheduling in the Planning Table
Occupied time
Line X1
Reqmt
Available
Material data
Material Y
Reqmts
Available qty
Production line X1
Production line X2
Not yet assigned
Material Z
Reqmts
Available qty
Production line X2
Not yet assigned
UoM Due
%
hr
hr
8
UoM Due
09.04.
09.05.
100
8
8
25
2
8Occupied time (planned
09.04.
5.9.2001
takt time and number of
order quantity combined with
processing stations)
pc
pc
pc
200
100
200
100
pc
pc
pc
200
200
200
200
200
The planned orders are
scheduling using the takt
time/rates of the line
hierarchy
200
Assignment mode
 SAP AG 2004

If you access the planning table using the Sequencing selection, the planned orders are then
scheduled in the planning table using the takt time/rate of the line hierarchy.
The load of the production line is determined by comparing the occupied time with the available
capacity of the production line (standard available capacity or shift program).

In the planning table, you can change the operative rate/takt time for a certain period of time. The
operative takt time/rate overrides the maximum takt time/rate maintained in line design.

Using the Totals Display in the planning table, you can convert the capacity data display from a
display according to time unit to a display in the unit of measure. Then in the available capacity row,
the system displays the maximum quantity that can be produced on the production line and in the
capacity load row, system displays the quantity that is already planned.
In the totals display, you can also switch between the views Free or Occupied. If you set the view to
Free, you can check how much time has not yet been occupied or how many pieces you can still
produce.
© SAP AG
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Takt-Based Scheduling: Example
Line S2
Planned rate: 30 pc / hr
(planned takt time: 2 mins)
1
2
Production Line
Line
segment
20 mins
1
A
B
2
A
B
3
A
06:00
Line hierarchy
(Number of takts:
3)
3
Maximum rate: 60 pc /
hr (minumum takt time:
1 mins)
Scheduling of planned order A
Lot size
10 pieces
Production start: 06:00 min
Production end:
06:22:00 AM min
Execution time:
22 mins)
B
06:10 06:20 06:30 06:40 Time
Scheduling: Planned order B
Lot size
10 pieces
Production start: 06:20:00 AM min
Production end:
06:42:00 AM min
Execution time:
22 mins)
1 mins
 SAP AG 2004

This example shows the scheduling of two planned orders with lot size 10 (planned order A and
planned order B). In this example, the planned rate/takt time of the current period is smaller than the
maximum rate/takt time.
By increasing the planned rate/takt time in the direction of the values of the maximum rate/takt time,
you can increase the yield of the production line.

Number of takts: The production line consists of three line segments each with one takt (line
segments 1, 2 and 3). This means every product must flow through 3 takts.

Maximum rate/takt time: A maximum rate of 60 pieces per hour has been defined for the line
hierarchy. This corresponds to a takt time of 1 minutes. The takt time is the length of time that a
material is processed in one takt (also line speed).

Planned rate/takt time of the current period: The planned rate defined for the current period in
line balancing is 30 pieces per hour. This means that a material is placed on the production line at
line segment 1 every 2 minutes.

Scheduling: The system dispatches planned orders to the earliest possible point and calculates the
start and finish times on the work centers of the production lines. If a product goes through several
line segments (for example, processing stations) of a line hierarchy, the system calculates the
production start time on the first station and the production finish time on the last station.
Here, the system uses the following formula to calculate the execution time for the planned order:
(Number of takts - 1) * minimum takt time + planned takt time + planned order quantity

The maximum rate represents the line speed. As opposed to the planned rate (line-on speed), this
cannot be maintained dependent on time (which is often necessary). If you choose the indicator
Basis for Takt-Based Scheduling when maintaining the line hierarchy, the system uses the planned
rate which can be maintained dependent on time as well as the line-on speed and the line speed for
scheduling. Restriction: The line-on speed is identical to the line speed.
© SAP AG
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Visualization in the Graphic Sequence Schedule
Disp./reallocate
Line
Time
Deallocate
12.08.
15
30 45
Reschedule
Planning duration: 1 day
Sequence
schedule 12.09.
00 15 30 45
15
30 45
00 15 30 45
12.10.
15
30 45
14:00:00
16:00:00
18:00:00
Line S2 06:00:00
10:00:00
Legend
Legend
Visualization
Visualization
12:00:00
Material SA
08:00:00
14:00:00
Material SB
16:00:00
18:00:00
Line
Row
Line S2
Orders not yet dispatched
12.08.
12.09.
12.10.
1
2
 SAP AG 2004

Use: You can branch to the graphic sequence schedule from the planning table. Using the graphic
sequence schedule in make-to-stock repetitive manufacturing provides you with a graphic overview
of the production quantities (whereas in make-to-order repetitive manufacturing the sequence
schedule is also used for sequencing the planned orders).

Visualization:
• In order to display as many planned orders as possible simultaneously on the screen, the time
axis is folded in the sequence visualization.
• The planned orders can be displayed using different colors to represent different criteria. A full
range of visualization profiles are provided for this purpose.
You can create the visualization profile in Customizing for Repetitive Manufacturing in the
work step Sequencing. In the graphic sequence schedule, you can specify a visualization profile
as a user-specific setting.
• In the sequence schedule, the work-free time (e.g. breaks) of the production line is displayed in
a gray shaded area so that it can be easily distinguished from the operating time (lighter
shading). Here, the standard system uses the scheduling-relevant capacity in the work center of
the header of the line hierarchy.
© SAP AG
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Planning Takt-Based Flow Manufacturing:
Summary
 Takt-based scheduling in takt-based flow
manufacturing
 Takt-based flow manufacturing with direct use of
the graphic sequence schedule especially for
make-to-order production (often high order
volume, small lot sizes)
 Takt-based flow manufacturing with direct use of
the planning table (graphic sequence schedule
here only for visualization purposes) especially
for make-to-stock production (often small order
volume, larger lot sizes)
 SAP AG 2004
© SAP AG
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Important Acronyms
APO
- Advanced Planner and Optimizer
ATP
- Available To Promise
BW
- Business Information Warehouse
CIF
- Core Interface
CO
- Controlling
CO-PA
- Profitability Analysis in Controlling
DI
- Discrete Industries
DP
- Demand Planning
DRP
- Distribution Resource Planning
OF
- Order finish date
SPLAN
- Single item planning segment
OS
- Order start date
PR-ORD
- Production order
FI-SL
- Special Purpose Ledger in Financial Accounting
PRT
- Production resources/tools
IDES
- Internet Demonstration and Evaluation System
iPPE
- Integrated Product and Process Engineering
IO
- Individual customer order
WO
- Warehouse order
LIS
- Logistics Information System
MM
- Materials Management
MRP
- Material Requirements Planning
OLTP
- Online Transaction Processing System
PC
- Personal Computer
RSQ
- Run schedule quantity
Grp. Ct.
- Group counter
PS, PSL
- Production stor. location
Pld. ordr
- Planned order
PP/DS
- Production Planning and Detailed Scheduling
PPM
- Production process model
PPC
- Production planning and control
PPT
- Product planning table
PP
- Production planning
PR-ORD
- Process order
PS
- Production start date
WIP
- WIP location (work-in-process)
QM
- Quality Management
REM, RM
- Repetitive Manufacturing
© SAP AG
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SCM
- Supply Chain Management
FAP
- Float after production
SNP
- Supply Network Planning
SOP
- Sales and Operations Planning
FBP
- Float before production
PIR
- Planned independent requirement
GI
- Goods issue
GR
- Goods receipt
WIP
- Work in process
WM
- Warehouse Management
© SAP AG
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Unit: Overview Capacity Planning
 SAP AG 2004
© SAP AG
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Overview Capacity Planning
Contents:
 Integration of Capacity Planning
 Environment of Capacity Planning in R/3 and APO
 Overview over Contents and Display Types
 SAP AG 2004
© SAP AG
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Course Objectives
At the conclusion of this course, you will be able to:
 Have an Overview over the usage of capacity
planning within SCM and over main contents of
capacity planning.
 SAP AG 2004
© SAP AG
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Course Content
Preface
Unit 1
Introduction
Unit 2
Course Overview
Unit 3
Capacity Evaluation
Unit 4
Capacity Leveling
Unit 6
Scheduling and
Capacity Requirements
Unit 7
Capacity Leveling
(in graphical form)
Unit 8
Further Planning
Functionalities
Unit 9
Summary
(in tabular form)
Unit 5
Available Capacity
Appendix
 SAP AG 2004
© SAP AG
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© SAP AG
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Main Business Scenario
 The manufacturing company for which you work
aims to deliver orders received by the dates
promised. You therefore want to provide sufficient,
but not excessive, available capacity at the work
centers to cover the capacity requirements
generated by orders. This is why you use capacity
planning, for example, to spot overloads in time, to
carry out capacity leveling for the requirements
dates based on available resources, and to fix
these capacity requirements.
 SAP AG 2004
© SAP AG
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Course Overview: Business Scenario 1
 You are running a manufacturing company
and want to obtain an overview of capacity
planning. You therefore want to find out
about the capacity planning environment,
and about available capacity and pegged
requirements, in particular.
 SAP AG 2004
© SAP AG
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Course Overview: Business Scenario 2
 You intend to plan the resources of your
company. Therefore you will need the
capacity requirements also for demand
planning. This is possible if you roughly
include a routing when creating the
demand plan. These requirements will be
propagated althrough the process chain to
be able to predict capacity requirements
for each of your planning steps.
 SAP AG 2004
© SAP AG
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
Supply Chain Planning is usually broken down into several steps. Different components can be used
to execute these steps in R/3 and/or APO (Advanced Planning and Optimization). It is therefore
possible and useful to use both systems in an integrated system for planning. System integration
takes place via the CIF interface (Core Interface).

Demand Planning (used to derive a future demand program from the demand figures in the past) can
either be executed in R/3 in Flexible Planning (with the special case of standard SOP - Sales and
Operations Planning), or in APO in Demand Planning.

Actual Demand Management is carried out in R/3. However, it is also possible to derive planned
independent requirements from APO-DP.

Sales orders are always created in R/3. Global ATP checks on sales orders can take place in APO
(integration with PP/DS is also possible).

Cross-Plant Planning is possible with APO Supply Network Planning.

Material Requirements Planning can be executed in either R/3 or APO. Capacity Planning is
executed separately in a second step in R/3. However, quantities and capacities can be planned
simultaneously in APO-PP/DS (PP/DS: Production Planning/Detailed Scheduling).

Production execution, in other words, the processing of manufacturing orders (production orders or
process orders) takes place in manufacturing.
© SAP AG
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
Master data, planned orders and production orders provide data that can be used to represent
available capacities and capacity requirements.

In APO, the master data comprises products, production process models (PPMs) or PP/DS runtime
objects and resources. R/3 should therefore be the master system for master data maintenance and
the CIF interface should be used to transfer data to APO.

The available capacity is a measure of the work that a resource can perform per workday.

The capacity requirement is a measure of the work required by the individual orders at a resource at a
certain point in time.

In Scheduling you determine the times of the capacity requirements.

In the capacity evaluations, these requirements can be compared with the available capacities.

In capacity leveling, overloads and under-utilization can be leveled. You can use alternative suitable
resources for processing or you can use the sort criteria to plan optimal loading.
© SAP AG
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Capacity Planning/Elements
Available capacity
t
Scheduling
10 20 30 40 50
Capacity requirement
t
Capacity evaluation/leveling
evaluation/leveling
Capacity reduction
4 434518 759691
 SAP AG 2004

The available capacity represents the capacity available for production at a work center or resource.

You can schedule the sequence of operations to determine the times for the capacity requirements.

To calculate the capacity requirements, the system uses formulas containing the dates and quantities
for production requirements.

The capacity evaluation gives you an overview of the load and the production requirements.

Capacity leveling allows you to achieve optimal planning and an optimal load.

Capacity reduction occurs when operations are confirmed or order quantities are reduced or
cancelled.
© SAP AG
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Display Types
Charts
Evaluations
Available capacity
Overviews
Capacity requirements
Lists
Tabular Capacity Planning Table (R/3)
Graphical Capacity Planning Table
 SAP AG 2004

Capacity planning uses several display types. It uses evaluation lists, block diagrams, bar charts, line
charts and Gantt charts.

You can also use the tabular capacity planning table or the graphical capacity planning table (also
known as the capacity planning table) to carry out simulations.
© SAP AG
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Capacity Evaluation
Contents:
 Capacity overviews
 Order detail lists
 Graphics
 SAP AG 2004
© SAP AG
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11-13

In the R/3, you can access capacity evaluations from two menu options:
 The Work Center View menu option accesses evaluations for loads, orders, pools of orders,
backlogs or overloads.
 The Variable menu option allows you to access evaluations using profiles created for your specific
needs.

When accessing the capacity evaluation in the R/3, the settings are pulled from the overall profile.

This overall profile can be one provided by SAP or a user-specific profile.

To access the evaluation via the work center, you can use standard profiles and user-specific profiles.

You can change the display using the menu option Settings.

You can use the menu Selection to increase or restrict the selection criteria for the capacity
evaluation.
© SAP AG
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Capacity Leveling in Table Form
Contents:
 Use of the tabular capacity planning table
 Dispatching procedure
 Preview of the capacity planning table
 SAP AG 2004
© SAP AG
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Capacity Leveling Measures
Increase available capacity
Alternative work center
Date shift
Sequence planning
External
External assignment
assignment
Lot
Lot reduction/splitting
reduction/splitting
 SAP AG 2004

To achieve the objectives listed in the preceding slide, you have several options:
 Adjust the available capacity by increasing the standard available capacity for the relevant
capacity category or by inserting a time-restricted interval of available capacity in order to
increase the available capacity.
 Determine an alternative work center with remaining available capacity, for example, by using a
work center hierarchy to call up the planning table.
 Use scheduling (either finite scheduling or manual scheduling on the planning table) to find a
period with sufficient remaining available capacity.
 Form optimal sequences to reduce setup times.

You can only reduce/split the lot, or specify that operations are to be assigned externally, in the
production order.
© SAP AG
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Capacity Leveling Interfaces
Tabular Capacity Planning Table
Capacity Planning Table
Work center: Turning Capacity: Machine
06.00
CW 25
CW 26
10.00
14.00
18.00
CW 27
Av. capacity
Dispatched
Pool
Order 100012 Operation 0010 Start 03.05.
Order 100014 Operation 0020 Start 15.05.
Order 100234 Operation 0030 Start 06.06.
Order 100333 Operation 0010 Start 09.05.
Order 100456 Operation 0050 Start 01.05.
 SAP AG 2004

The capacity planning module in SAP R/3 has two interfaces.

The main capacity planning module and its various views:
 Work center view: Here you restrict the selection for specific work centers. Work centers and
capacities are displayed in the planning tables.
 Individual capacity view: Here you restrict the selection to specific work centers. You can dispatch
operations both to work centers/capacities and to the corresponding individual capacities.
 Order view: Here you restrict the selection to specific orders. All the work centers and capacities
affected are displayed for one or more orders.

Leveling can also be carried out directly from production order maintenance. Depending on the
overall profile set for the production controller, you branch to either the capacity planning table or
the tabular capacity planning table. If no overall profile has been stored for the production scheduler,
the capacity planning table is called up using the overall profile SAPSFCG001.
© SAP AG
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Scheduling Procedure
Determining the dispatching date
- using scheduling or manually by the user Specifying the dispatching sequence
- when dispatching several operations Carrying out checks at the time of scheduling
- checking dates and work center -
Carrying out finite scheduling
Checking the dispatching results
- Operation date -
Writing
a
planning
log
Setting the “dispatched” status
Carrying out midpoint scheduling
 SAP AG 2004

The main function of capacity leveling is to dispatch operations. Operations are dispatched in order
to fix them at a point in time when there is sufficient capacity for them to be carried out.

If you have set the Finite scheduling indicator in the strategy profile, the system looks for remaining
available capacities depending on the planning direction.

If necessary, the user can specify another work center during dispatching. The work center cannot be
locked or marked for deletion.

Operations with the “dispatched” status can only be moved using the planning table after an order
has been changed.

A planning log is written for all planning activities.

If errors occur during dispatching, the process can be terminated (you can make this setting in the
strategy profile).

Midpoint scheduling is dealt with in detail in the Scheduling and Capacity Requirements unit.
© SAP AG
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APO Product Planning Table: Construction
(Example)
Product planning table
Periodical resource view
22.06.03
22.06.02 24.06.03
24.06.02 25.06.03
25.06.02 26.06.03
26.06.02 27.06.03
27.06.02 28.06.03
28.06.02 01.07.03
01.07.02 02.07.03
02.07.02
Periodical
Periodicalresource
resourceview
view
Resource
WT-L100_1200_002
WT-L200_1200_002
Navigation tree
WT-L100_1200_002//Auslas....
Auslas....
WT-L100_1200_002
Reqmts
Reqmts
Available
Available
%
%
20,710
100
100
100
100
HH
HH
1,450
1,450
7,000
16,000
7,000
7,000
7,000
7,000
16,000
7,000
16,000
7,000
16,000
7,000
16,000
7,000
16,000
WT-M00_1000_002 / Auslas....
WT-L200_1200_002
WT-L100_1200_002 / Auslas....
%
%
%
Periodical product view
Periodical product view
T-F200
T-F1300 / Maxitec Computer
Available qty
Available qty
Range of Coverage
Range of Coverage
VP-BED / 20 / PLANNING
VP-BED / 20 / PLANNING
PL-ORD / T-F200
PL-ORD / WT-L100_1200_002
Total Reqmts/ Stock
PL-ORD / WT-L200_1200_002
Pc
Pc
Day
Day
Pc
Pc
Pc
Pc
Pc
Pc
100
24,641
100
100
100
100
7,000
7,000
7,000
7,000
16,000
50
7,000
8,000
50
7,000
16,000
50
100
22.06.02 24.06.02 25.06.02 26.06.02 27.06.02 28.06.02 01.07.02 02.07.02
22.06.03 24.06.03 25.06.03 26.06.03 27.06.03 28.06.03 01.07.03 02.07.03
200200
99.999
200200
129.999
200200
139.999
200200
149.999
200680
159.999
200680
169.999
200680
19
9.999
2001160
20
9.999
480
480
Total Reqmts/ Stock
Periodical product view
Charts
Shown
Periodical resource view
Periodical product view
Hidden
Alert Monitor
Product view individual elements
Chart selection
 SAP AG 2004

The APO product planning table (transaction: /SAPAPO/PPT1) enables the work scheduler to
process the master plan. You can check the production quantities at a glance, change it if required
and create new production quantities. You can also determine the capacity load utilization of the
resources as well as the product's availability situation. You can also execute a pegged capacity
where-used list.

The product planning table represents a tool with extensive functions, from which planning in APO
PP/DS can be performed and evaluated. There are several screen areas available that you can display.
Depending on your selection of the charts, you can adjust the product planning table to various tasks.

The navigation tree in the upper left displays the work scope of the product planning table. You can
use the tree to define which objects are displayed in the various views. It allows you, for example, to
form groups according to planner, product group, location, or resource. There are also subnodes for
in-house production and the bill of material. You can also hide the navigation tree.

At the lower left screen edge, you can Drag&Drop the charts (such as Periodic product view,
Periodic resource view, Alert Monitor, Quantity graphic, Periodic production view, and so on) you
want to display. You can show a maximum of three charts at one time (in addition, for example, to a
detailed view of the planned order). In the periodic views, there is also a menu for accessing the
typical characteristic lots (such as in the product view for fixing, and for the conversion indicator, in
the resource view for the operation time/downtime). Repetitive manufacturers might typically use the
following two charts (these charts are displayed on the right-hand side of the screen):
 Periodical resource view: Requirement and capacity of the resources (production lines) are
displayed. The system determines their percentage utilization.
 Periodical product view: The system displays the products for the resources, the order quantities
to manufacture in each period, as well as detailed information about dates and quantities. In this
area you can choose to perform manual or interactive planning.
© SAP AG
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
The APO product planning table is mainly used in repetitive manufacturing for period-oriented
planning. There are also numerous links to more extensive planning tools such as the Product View
(Single Elements), the Alert Monitor, or the Detailed Scheduling Planning Board, where you can
also display charts. As well as manual planning, you can also start planning heuristics and the PP/DS
optimizer from the product planning table.
© SAP AG
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Models and Planning Versions in APO
R/3
Master Data
Master data in
Active model 000
Locations
Resources
Products
PPM
Simulation
model Z01
Resources
PPM
Transportation
lane
Active planning version 000,
version-dependent master
data and transaction data
APO
Planning version 1,
version-dependent master
data and transaction data
Planning version Z01,
version-dependent master
data and transaction data
 SAP AG 2004

The supply chain model (abbreviation: model) represents the complete supply chain from the
vendors via the production and distribution locations to the customers. It contains locations,
transportation lanes, products, resources and production process models. This model is therefore the
basis for all planning functions in APO; it only contains master data.

The master data from the R/3 system is automatically assigned to the active model (model 000) when
it is transferred to APO. The active model represents the supply chain actually used in the company.
All transferred master data is therefore automatically available for operative planning model 000. If
you manually create master data in APO, you must explicitly assign it to a model.

For simulation purposes, you can create several planning versions for each supply chain model.
However, only model 000 and planning version 000 are active. The planning version contains master
data and transaction data. In an inactive planning version, you can increase simulative planned
independent requirements, for example, and then plan production assuming increased demand. The
results of planning in the inactive planning versions cannot be copied to the active planning version.
The planning activity must be repeated in the active planning version.

Models and planning versions can be copied using version management or they can be created
manually. However, they must be clearly marked so that two planning versions in different models
do not have the same name. The active planning version 000 only exists in model 000.
© SAP AG
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Propagation Range
 The propagation range determines the resources and
products for which a planner can change the planning.
 This includes
 creating and changing orders for these products
 changing the capacity and planning parameters of
these resources
 rescheduling operations on these resources
 The “From work area” indicator determines that the system
copies the resource selection from the work area into the
propagation range.
 SAP AG 2004

In the propagation range, you determine the resources and products that you can plan in Production
Planning and Detailed Scheduling.

The resources of the propagation range are relevant for resource-related planning. You can only
change the planning for resources of the propagation range, in other words, you can only schedule or
reschedule operations on these resources, for example.

The products of the propagation range are relevant for product-related planning. You can only
change the planning for products of the propagation range. In other words, you can only create
orders (for example) for these products.
When you create an order for a product in the propagation range, and the product contains
components that are not contained in the propagation range, the system is unable to create orders for
these components. Instead, the system writes a planning file entry for these components.

Note: You use the work area to determine which objects are displayed in the planning board that you
call directly (and only from the Production Planning and Detailed Scheduling screen). Propagation
ranges with the “From work area” indicator cannot be used in the product planning table.
© SAP AG
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Available Capacity
Contents:
 Options for maintaining available capacity
 Factory calendar
 Work center hierarchy
 SAP AG 2004
© SAP AG
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Work Center Data - R/3
General data
Default values plan
Capacity data
Scheduling data
Basic data



Name and description
Standard value key
Efficiency rate key
Default values


Control key
Standard text key
Capacity


Available capacity
Formula key
Scheduling



Scheduling basis
Queue and move times
Formula key
 SAP AG 2004

The work center contains several groups of data that are located on different screens. This example
shows the most important ones for capacity planning.
© SAP AG
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Available Capacity at the Work Center
Capacity
Plant:
Capacity:
Capacity cat.:
Default capacity
1000
ABC
003
Default values for each
capacity category
For example:
001
Reference available capacity
Work center
Capacity cat.:
Capacity:
003
ABC
Capacity cat.:
001
Capacity cat.:
Capacity:
002
Group
Pooled capacity
Plant: 1000
Capacity: Group
Capacity cat.: 002
 SAP AG 2004

The reference indicator is set in the work center for the available capacity of a pooled capacity and
therefore cannot be changed.

The available capacity of both an external capacity and a default capacity is copied to a capacity
category at a work center and can be changed there.

A reference indicator can also be set for an external capacity.
© SAP AG
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Using Key Shift Sequences to Maintain Available
Capacity
Day 1
Day 2
...
Day 5
Shift definition
Shift 1
Shift 1
Shift 1
Work start
...
Work finish
Shift sequence
Breaks
Shift 2
Shift 2
Shift 3
Shift 3
Shift 2
Capacity
 SAP AG 2004

Shift sequences and shift definitions can be used to maintain available capacity in detail for each
capacity category, but only by using intervals of available capacity.

Shift sequences and shift definitions can be created and selected for specific parts of Customizing
using the Grouping key.

In a shift definition, you can define the work start, work finish and break times for all work centers.

In shift sequences, the specific sequence of shift definitions is maintained for all work centers.

By changing the shift definition, you can automatically change available capacities that have shift
definitions.
© SAP AG
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Resources in APO
 Single-activity resources (PP/DS)

Time-continuous

Available capacity for one activity
 Multiactivity resources (PP/DS)

Time-continuous

Available capacity for several activities
 Bucket resources (SNP)

Time intervals

Available capacity for each time
interval
 Mixed resources (PP/DS and SNP)
 SAP AG 2004

Resources are APO master data where you define the capacities and working times of machines,
labor, means of transport and stocks. You can create resources using the CIF transfer from R/3 work
centers into APO.

You can define resources as single-activity resources, multiactivity resources, or bucket resources.
These single-activity and multiactivity resources can be used for continuous and exact temporal
planning in Production Planning and Detailed Scheduling (PP/DS). You can use bucket resources for
medium and long-term planning in Supply Network Planning (SNP). The time periods (buckets) for
bucket resources are at least one day long.

You can use mixed resources both in SNP (bucket-oriented planning) and in PP/DS (time-continuous
planning).
© SAP AG
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Capacity Data for the Resource
A single-activity resource can execute an activity at a specific time and
therefore only has two states: It is either reserved by a resource, or it is not
reserved.
Therefore, for a single-activity resource, the capacity value with the
nondimensional capacity of one is hard coded in the system.
On a multiactivity resource, several activities can be executed at the
same time.
To model the multiple load, define a capacity for a multiactivity
resource, in addition to the working time data.
Capacity: Nondimensional 5
Capacity: Meter 4
On this resource, there are five
identical machines available to
process five operations.
On this resource, any number of
activities can be scheduled at the
same time, provided the total length
of the individual activities does not
exceed the capacity.
 SAP AG 2004

On a single-activity resource, only one activity can be executed at any one time.

Several activities can be executed at the same time on a multiactivity resource. Each activity
executed on a multiactivity resource consumes a particular part of this capacity. The number of
activities scheduled at the same time is determined by how much capacity is available.
© SAP AG
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Maintaining Detailed Available Capacity
Options for maintaining an alternating available capacity
With shift sequence
Without shift sequence
1. Create shift factors
1. Call capacity profile
2. Create break patterns
2. Change capacity to
current date
3. Create shifts
4. Create shift sequence
5. Assign shift sequence
as a capacity variant
 SAP AG 2004

If the available capacity on a resource is not the same every day, you can work with capacity variants
or change the capacity profile for each individual day.

You need shift sequences to use the capacity variants. You maintain these in several steps on the
header data screen of the resource by pressing the Definitions button.

To determine a shift sequence for planning in PP/DS, you need shift factors, breaks and shifts. The
definitions for quantities and production rates are only used in bucket resources.

You can use this capacity profile maintenance to maintain the capacity in detail for shifts and
intervals. In this case, capacity profile maintenance has certain advantages over capacity variants
maintenance:
 You can change to times and rates of capacity utilization without having to maintain a new shift or
interval. It is then obvious which day the changes are for.
 The changes only refer to the selected resources.
© SAP AG
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Scheduling and Capacity Requirements
Contents:
 Views of capacity requirements
 Formulas
 Scheduling
 Ways of reducing the load
 SAP AG 2004
© SAP AG
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Scheduling Types
Scheduling type
Order start date
Forward scheduling
Order finish date
Backward scheduling
Today’s date as basic start
Current date scheduling
Special types
Today scheduling
As of current date
Midpoint scheduling
As of operation
Finite scheduling
Check capacity availability
 SAP AG 2004

The scheduling types (forwards, backwards) are to be assigned to the appropriate order types as
default values.

The special types are, excluding today scheduling, planning functions of capacity planning.

Today scheduling is automatically triggered for orders with a start date in the past.

When dispatching the operations of orders, midpoint scheduling is automatically executed for the
non-dispatched operations of this order.

Finite scheduling takes into account the available capacity at the individual work centers.
© SAP AG
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Midpoint Scheduling I
1st example: A dispatched operation
Before dispatching
10
PS
20
30
SS
SF
PF
Dispatch operation
20
Forward scheduling &
backward scheduling
10
20
SS
30
SF
 SAP AG 2004

The above example shows the process of dispatching an operation.

Midpoint scheduling is always executed when at least one operation is dispatched.

With midpoint scheduling, the order is not scheduled starting from the order start or order finish
date. Instead, it is scheduled starting from the dispatched operation.
Note:
▪ PS = planned start
▪ PF = planned finish
▪ SS = scheduled start
▪ SF = scheduled finish
© SAP AG
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Finite Scheduling
Prerequisites and Procedure
Strategy profile
Work center/capacity



Indicator: Relevant for finite
scheduling

Indicator: Finite scheduling on

Search direction forward/backward
Overload factor for permissible
overload
Can be used by several operations
Time profile

Search period for remaining available
capacity
Sufficient available capacity at relevant date?
Move the operation to a date without
capacity problems
 SAP AG 2004

When using finite scheduling to dispatch operations, the system takes into account the current
capacity loads of the capacities.

In finite scheduling, only those capacities for which the Relevant for finite scheduling indicator has
been set are taken into account. By not setting this indicator, you can exclude a capacity with
sufficient available capacity from finite scheduling.

Conflicts that arise between the operation dispatched and other operations in the order that have been
dispatched and/or with the order itself do not lead to an automatic dispatching correction.

For each operation to be dispatched, the system checks whether remaining capacity is available for
the operation at the date determined. If the operation has suboperations relevant to scheduling, the
system also looks for available capacity for these suboperations.

If there is sufficient available capacity, the system dispatches the operation. If there is insufficient
capacity, the system moves the operation to a date when it can be processed without any capacity
problems. You can specify the search direction in the strategy profile using the Plan. direction
forwards indicator. The period for the search for remaining available capacity is specified in the time
profile in the Planning period section.
© SAP AG
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Scheduling/Time Elements in an Order
Float bef. Op. Op. Op. ........ Op. Float after GR proc. Pick/pack
prod.
0010 0020 0030
0099 production
time
time
OS
SS
Queue
time
ES
SF
Setup
time
OF
Process. Teardown Wait
time
time
time
SS
AD
LD
Load
time
Transit
time
GI
DDD
Move
time
SF
Order dates
Operation dates
OS
SS
Order start date
Scheduled start date
(production start date)
SF
Scheduled finish date
OF Order finish date
AD Anticipated availability date
LD
Load date
GI
Goods issue date
DDD Desired delivery date
Time concepts
ES Earliest start date
LS Latest start date
LE Latest end date
Lead time for order
or operation
Float times for orders
Lead time for operation
Interoperation times
Processing times in sales
 SAP AG 2004

The two order floats have different purposes:
 Float before production
 Float after production
- date shift, capacity planning
- allow for disruptions, capacity planning

The order floats can be predefined in Customizing and in the material master (using the scheduling
margin key).

The duration of an operation comprises a maximum of five time elements:
 Queue time: can also be used in capacity planning
 Setup time, processing time, teardown time
 Process-specific wait time.

The duration of the move time lies between two operations, but it is assigned to the preceding
operation.

The material requirements are scheduled to the earliest start date (this can be changed in
Customizing).

The capacity requirements can be displayed at the earliest or at the latest start date.
© SAP AG
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
After the lot size of the planned order and the PPM explosion is determined, the production planning
run calculates the schedules and requirements of the planned order.

The system uses a material staging according to how the components are assigned to the activities in
the PPM. The dependent requirements date for the BOM components is the production start date for
the operations assigned to them.

To determine the requirements dates of the components, the activities are scheduled on the resources.
Scheduling is carried out in accordance with the settings maintained in the strategy profile, in other
words, the system takes account of the constraints defined there (component availability and
resource capacity, for example).

Constraint violations, for example, if a customer requirement date cannot be kept, or if the capacity
exceeds a finite resource, are displayed as alerts. The planner can then postprocess the planning
results manually.
© SAP AG
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
Capacity requirements are reduced or deleted by order confirmations, setting orders to one of the
“Lock” or “Technical completion” statuses or by setting the deletion indicator.

The following confirmations result in a change in the capacity requirements:
 Confirming quantities
 Confirming forecast standard values
 Confirmation on another work center
Note: PDC = plant data collection
© SAP AG
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Capacity Leveling in Graphical Form
Contents:
 Handling in the Detailed Scheduling Planning Board
 Scheduling Variants
 Scheduling Strategies
 Functions/Heuristics of the Detailed Scheduling
Planning Board
 SAP AG 2004
© SAP AG
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Capacity Planning Table
Work centers
Work center
12:00
18:00
00:00
Tuesday
06:00
18:00
00:00
Tuesday
06:00
Chart
00:00
Monday
06:00
14100
lathe
14200
lathe
Pool
Op.
Qty
2010
0010
10
2020
0020
5
2030
0010
10
00:00
Monday
06:00
12:00
Chart
Order
Message line
Table section
Diagram section
 SAP AG 2004

The capacity planning table enables you to carry out detailed planning of capacity requirements
continuously over time.

The capacity planning table consists of several charts arranged horizontally in which the available
capacity (operating time) and the capacity requirements (operation duration) are grouped according
to various criteria and can be displayed on the same axis. For example, all the capacity requirements
for one order, or all the capacity requirements that have been scheduled on one capacity, can be
grouped together.

Each chart can have its own title bar and it comprises a table section and a diagram section:
 The table section contains information for identifying and describing the objects displayed in the
diagram section.
 The diagram section has a window on the virtual time axis in which the available capacity and the
capacity requirements are displayed in graphical form with the start and finish date. This window
displays the same section for all the charts. You can change this section as much as you like by
altering the scale.
© SAP AG
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
When you call up capacity leveling and capacity evaluations, all the necessary settings are taken
from an overall profile. This overall profile can be a profile provided by SAP or a user-specific
profile.

For capacity leveling, the relevant overall profiles are tied to a menu option but you can access them
using the appropriate USER parameters.

If an overall profile is called up for a capacity planning table, the profile for the tabular capacity
planning table and the period profile is not required.

If an overall profile is called up for a tabular capacity planning table, the profile for the capacity
planning table is not required.
© SAP AG
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Strategy Profile
Overall profile
Strategy profile









Planning direction
Finite scheduling yes/no
Insert operation/Close gaps
Dispatching at the earliest time
Date entry when dispatching
Cancel dispatching due to error
Using order/operation floats
Handling queue times
Operation date check

Dispatching sequence

Midpoint scheduling yes/no

Overall capacity load
 SAP AG 2004

The strategy profile is part of the overall profile for capacity planning and is used to define the
parameters for an individual planning strategy.

Different strategies profiles reflect different planning goals.

You can switch the profile interactively during planning.

If the Cancel dispatching due to error indicator is set, dispatching is cancelled if errors are detected
when the system checks the operation dates and order dates. The system always writes a log.
© SAP AG
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Planning Direction
Today
Planning
direction
forwards
Planning
direction
backwards
Dispatching
at the earliest
time
Operation
in worklist
 SAP AG 2004

The planning direction determines the search direction for remaining available capacities if the
original operation dates are not available.

With automatic scheduling, the system searches in the future for a possible dispatching date within
the planning period.

When the Change planning direction indicator is set, the system changes the planning direction
when searching for remaining available capacity if it does not find any in the planning period in the
planning direction. If this indicator is not set, dispatching occurs in the past.

When the system dispatches operations at the earliest point in time, it does not take into account the
dispatched dates of the operation. With this planning strategy, you can achieve a capacity
commitment without any gaps by using the Plan. direction forwards setting.
© SAP AG
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Insert Operation/Close Gaps
Inserting an operation
Closing gaps
 SAP AG 2004

On the capacity planning table, operations can be inserted in a capacity commitment that already
exists. The operations that have already been dispatched are moved according to the planning
direction without changing the sequence. The capacity must not allow multiple loading.

The Close gaps function is used when a dispatched operation is deallocated or rescheduled.
Depending on the planning direction indicator in the strategy profile, the operations that follow or
precede the rescheduled or deallocated operation are rescheduled (moved) to close the gap that has
arisen. You can define the direction and period concerned in the strategy profile. Therefore, this
rescheduling either finishes at the next gap or at the end of the planning period. You can achieve a
schedule without gaps by using the Dispatch at earliest point in time function.
© SAP AG
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Calling the Detailed Scheduling Planning Board
 When you call a menu option in the DS planning board, an
overall profile is called.
Menu paths in
the PP/DS menu
SET/GET parameters
for the menu paths
Views 1 to 3:
View 1
/SAPAPO/CDPS_VIEW_1
View 2
/SAPAPO/CDPS_VIEW_2
View 3
/SAPAPO/CDPS_VIEW_3
Standard overall profile
defined by SAP
Variable view:
Variable view 1
The user chooses the overall
profile when calling the
planning board.
 SAP AG 2004

In the Production Planning and Detailed Scheduling screen, you can call the planning board directly
with different overall profiles, in other words, with different settings. To do this, you first choose
Detailed Scheduling and then View 1, View 2, View 3 or Variable View.

If you call the Variable View, you must enter an overall profile to access the planning board. You
can choose subprofiles for the overall profile.

Profiles set by SAP are used in View 1, View 2 and View 3. If you want to work with other overall
profiles, you must assign the overall profile in the user maintenance of the SET/GET parameters
(System -> User Profile -> Own Data).

If you call the Variable View, you can still change the work area before you start the planning board.
For views 1 to 3, you can define in the overall profile whether it should be possible to change the
work area when calling the planning board.
© SAP AG
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Detailed Scheduling Planning Board in SAP-APO
Table section
Column
header
Line
Diagram section
Resource chart
Res.
Res.
type
Description
Res01
P
Loc01
Res02
P
Loc01
Res03
P
Loc02
22
KW33
00 02 04
22
KW33
00 02 04
06
08
10
12
14
16 18
20
22
00
02 04
06
08
14
16 18
20
22
00
02 04
06 08
20
22
00
02 04
06 08
Order chart
Chart objects
Order
number
Product
000001294
P
000001335
P
000001357
P
06
08
10
12
Product stock histogram
Product
Product 01
22
KW33
00 02 04
06
08
10
12
14
16 18
300
200
100
Charts
Order No.: 000001294
Message line
Graphical object
(operation, order)
 SAP AG 2004

In the planning board, the resource schedule is displayed in graphical form.

The planning board is used for interactive planning (for interactive processing and the removal of
alerts, for example).

You can call the planning board directly from the Production Planning and Detailed Scheduling
menu or from order processing.

You can determine the layout of the planning board, for example:
 The different charts (a resource chart and an order chart, for example):
 The field selection and field sorting for the columns in the table section of a chart
 The format of the rows in the table section
 The objects displayed in the diagram section of a chart, for example:
­ Operations or orders (graphical objects)
­ Histograms (curves for warehouse stock and resource utilization)
­ Network displays of operations and orders that form the time and pegging relationships between
operations and orders
 The layout of operations and orders in the diagram section.
© SAP AG
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Planning Board: Navigation
 Use the right mouse button to navigate within the relevant
screen areas (table and diagram parts):

Find objects for the table part on the time scale

Mark objects in color

Select objects (for example, those marked in color, and so on)

Expand/collapse multiple loading

Change the time scale (day, month, week, and so on)
 Zoom function
 Print charts
 SAP AG 2004

For detailed information on navigating in the detailed scheduling planning board, see the online help.

You can use a detailed scheduling strategy to determine the rules and specifications used by the
system to schedule or reschedule orders and operations on resources, and which conditions (for
example, product and resource availability) are therefore considered in the planning.
When you schedule or reschedule an operation that you have selected for planning, several more
operations may also be affected. To ensure that the planning remains consistent, the system must also
reschedule these operations. Rescheduling one operation can trigger a chain reaction in which further
operations are rescheduled.
© SAP AG
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Planning Board: Functions (1)
 Manual rescheduling of operations and orders (drag and
drop):

Date changes or

Rescheduling to alternative resources
 Display/change master data and order quantities
 Deallocate orders
 Change sorting
Additional planning functions with 4.0:
 Improved order processing
 Simulation version with deleted orders
 Simultaneous fixing intervals for several versions
 Undo for drag and drop, Reschedule & Deallocate functions
 SAP AG 2004

In the planning board, you can manually reschedule operations and orders using drag and drop.

You can change the planning situation by: changing resources (capacity, working times, and so on)
and/or changing orders (quantities and dates).

Deallocate orders: You can use this function to deallocate operations or orders, in other words,
remove them from the resource schedule. After deallocation, the operations or orders concerned have
the status “Deallocated”, but retain the same dates. You may use this function if you want to
determine the production dates for the operations of important orders first, and then insert the
operations of the less important orders in the planning afterwards.

The sorting of the line formatting can be changed for the selected chart.

Additional planning functions:
 Under Functions – Order, you have several different ways of processing orders.
 In future, saving a simulation version will imply information about deleted orders.
 You can simultaneously edit the fixing intervals for several (selected) resources. You can also
define planning intervals that only permit access to the resource in question within the interval
(outside the interval, the resource is fixed for planning).
 In future, an Undo function will be available for the following scheduling functions: manual
planning using drag and drop, the Reschedule function and the Deallocate function.
• Manual planning using drag and drop
• Reschedule function and the Deallocate function.
© SAP AG
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Planning Board: Functions (2)
 Detailed scheduling strategies
 Resource utilization
 Product stock
 Network view - orders/operations
 Evaluation lists

Operation list

Order list

Production overview
 Alert monitor
 SAP AG 2004

For the resource utilization, product stock and network views, you can determine static charts that are
to be permanently displayed in the planning board, or dynamic charts that you can show (or hide) in
the planning board.

An operation list lists all operations within the evaluation period that are scheduled at the selected
resources.

An order list displays all orders that are scheduled at the selected resources.

The production overview lists the quantities and status of the selected products, for example, the
quantities of a product that have been released and confirmed.

The alert monitor displays problems that appear during scheduling. For example, a resource overload
occurs or the delivery date is missed. In the alert monitor profile, you determine which alert
categories are to be displayed.
© SAP AG
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Work Area
Planned independent requirement
Products
Orders
Resources
Orders
Operations
Operations
Resources
Resources
Resources
from the products
in the work area
from the orders
in the work area
directly from
the work area
Planning board
 SAP AG 2004

You use the work area to determine which objects are displayed in the planning board that you call
directly from the Production Planning and Detailed Scheduling screen.

The work area provides a selection of resources, orders and products used by the system to determine
the resources transferred to the planning board according to the following selection options:
 The system determines all orders that belong to the product(s) specified in the work area. It then
determines the operations that belong to these orders and the resources used by these operations.
 For each order specified in the work area, the system determines the corresponding operations and
the resources used by these operations.
 Each resource mentioned in the work area is directly relevant for the planning board.

The system uses these resources to determine the objects displayed in the different charts (resource
chart, order chart, operation chart and product stock histogram).
Note: In the propagation range, determine the products and resources that can be scheduled in the
planning board.
© SAP AG
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Strategy Profile - Scheduling Mode
Finite
scheduling mode
Finite resource
Infinite
scheduling mode
The system considers the resource The system does not
consider the resource
utilization. It only carries out
utilization.
scheduling if there is sufficient
capacity.
The system generates
alerts in the case of a
resource overload.
The system does not consider the resource utilization.
Infinite resource
The system does not generate alerts if resource overloads occur.
The following finite scheduling modes exist:
Find gaps, insert operation, squeeze in operations, fill operation from behind,
insert operation and close gaps until the finish
 SAP AG 2004

Use the scheduling mode to determine how the system schedules or reschedules a selected operation
on a resource. You can generally carry out finite or infinite scheduling on a resource.

You use Finite and infinite scheduling to prohibit the system from exceeding the available capacity
of the resource when scheduling operations (finite scheduling). In addition, you can schedule as
many operations as you want on a resource at the same time (infinite scheduling). You can therefore
schedule an operation without considering the resource utilization, directly on the desired date by
using an infinite scheduling mode. For finite or infinite scheduling, you must choose a relevant
scheduling mode in the detailed scheduling strategy and specify in the resource whether finite or
infinite scheduling of the resource is to always take place.

With infinite scheduling of an operation, a resource overload may occur. This can be displayed in the
alert monitor for finite resources. You must therefore use a corresponding PP/DS alert profile. In the
resource, you define the maximum duration allowed for a resource overload, before the system
interprets this overload as a resource overload and generates an alert.

In the figure above, you see how the system reacts to a finite or an infinite resource when you use a
finite or infinite scheduling mode.
© SAP AG
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
Resource availability: As a rule, activities can only be processed during the regular working times
of a resource and are therefore also only scheduled in regular working times. Both finite or infinite
scheduling of activities can take place in working times, in other words, with or without taking into
account the resource capacity and the activities that already exist (which last longer than a relevant
working time and can be interrupted so that they can be scheduled).

Dates and planning directions: As of the desired date, the system searches for a scheduling date in
the set planning direction for the last activity (backward planning direction) or for the first activity
(forward planning direction) of an operation or an order. Here the system considers the settings in the
strategy profile, PPM and resources. When the first activity has been scheduled, the next activity
enters the planning direction, and so on, until all activities of the operation or order have been
scheduled. The system can never schedule an activity before the earliest or latest possible date
(depending on the application).

Find gap: With this finite scheduling mode, you can schedule an operation in the planning direction
in the first gap that is long enough and has sufficient capacity.
Note: You can only use this scheduling mode for resources to be planned using finite scheduling.
In the planning parameters of a resource, you define whether a resource is finite or infinite. With
infinite resources, the system schedules an
operation using infinite scheduling, or without considering the existing resource utilization on the
desired date.
© SAP AG
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
If the system cannot find a scheduling date in the planning direction until the earliest or latest
possible scheduling date, the system changes the planning direction and tries to schedule the
operation or order in the other direction as close as possible to the desired date. If this does not work
either, the system does not carry out scheduling or rescheduling.

When creating orders, the availability date of the order product is significant. Here, you generally
choose the backward with reversal planning direction so that scheduling is successful. By default, the
date for reversal of the planning direction is the current date plus/minus the offset time.

If, in your planning, you want to allow an operation start in the past, you can use the offset time to
set this in the strategy profile. To do this, specify a negative offset time.

You can enter a positive or negative offset time. With a positive time, you can only permit
scheduling after a certain timeframe as of today.
© SAP AG
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
You can use the Infinite scheduling scheduling mode to schedule an operation on the desired date,
without considering the resource utilization. With this scheduling mode, infinite scheduling is used
to plan both finite and infinite resources.

In the alert profile, you determine for which products and resource and in which situations the
system is to display alerts. Resource overload alerts are only displayed when you have defined a
resource as a finite resource.
© SAP AG
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Squeezing in an Operation
1st step
Insert operation at a defined
point in time
4
7
5
6
3
2
1
Today
2nd step
Rescheduling predecessor
and successor
Time
4
7
6
5
3
2
1
Today
3rd step
Check current
time constraints:
if violation:
-> move sequence
into the future
7
Today
Time
6
5
3
4
2
1
Time
 SAP AG 2004

Squeezing in an operation: With this finite scheduling mode, you can dispatch an operation in an
existing commitment on the desired date, even if there are no gaps or gaps that are too small in the
commitment on this date. The system generates, if necessary, a gap that is big enough by moving the
neighboring operations on the resource in both directions.

You can only use this scheduling mode for single activity resources to be planned finitely.
© SAP AG
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Strategy: Consider Relationships (1)
Resource 1
Resource 2
Min.: 24:00 h
Resource 3
t
Today
Min.: 12:00 h
Relationship
Resource available
Always consider
Resource reserved
Operations for order
 SAP AG 2004

Time relationships between activities: Time relationships that determine the time intervals
(minimum or maximum) that activities can have may arise between activities. The system always
considers the obligatory end-start relationships between the activities of an operation. If, for
example, you have specified a minimum interval of one hour for two activities of an operation, the
system cannot schedule these activities in such a way that they fall short of this time interval. Orderinternal relationships are predecessor/successor relationships between activities and time constraints
for the sequence of activities.

In the DS strategy, you can set whether or not the system is to consider the time relationships
between the activities of different operations.
© SAP AG
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Further Planning Functionalities
Contents:
 Sequencing
 SAP AG 2004
© SAP AG
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Sequencing 2
Deallocate
Schedule
Order
Capacity
Operation
PG
PSG
SG SSG
1
10
1
10
STD
1
10
1
20
10 mins
1
10
1
30
15 mins
1
10
1
40
20 mins
1
20
1
10
30 mins
1
20
1
20
0 mins
1
20
1
30
10 mins
1
20
1
40
15 mins
1
30
1
10
40 mins
1
30
1
20
30 mins
1
30
1
30
0 mins
1
30
1
40
10 mins
1
40
1
10
50 mins
1
40
1
20
40 mins
1
40
1
30
30 mins
0 mins
Dispatched
Work center
description
Center
1906
9:00
Paint 1
11:00
10:00
15mins 1/10
0min
1/10
10mins 1/20
12:00
15mins 1/40
Pool
Center
Order
SG
SK
600001540
1906
1
20
600001650
1906
1
10
600001666
1906
1
10
600001750
1906
1
40
9:00
10:00
11:00
15mins 1/20
15mins 1/10
15mins 1/10
15mins 1/40
12:00
 SAP AG 2004

In this example, the dispatching sequence is determined by the setup optimization function instead of
the sequencing key. During setup time optimization, the standard value for the setup is changed. As a
result, the values for the duration and capacity requirements are recalculated using the formulas.

The setup group key and setup group category are a prerequisite both for setup time optimization and
for the sort sequence.

An Initial setup state field has been integrated into the strategy profile. This field allows you to
maintain a predecessor operation for the first operation to be dispatched so that a setup time
adjustment can be executed. Operations are also deemed predecessor operations if they lie outside
the planning period but within the evaluation period.
© SAP AG
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Optimization in PP/DS
 Optimization: Changes the production dates/sequences and resource
assignment of existing operations/activities regarding the following criteria (no
orders are created or deleted):
W1* Total lead time
+
W2* Total setup times
+
W3* Total setup costs
+
W4* Maximum delay costs
+
W5* Total delay costs
+
W6* Total Mode Costs
Objective function =
MINIMUM
 SAP AG 2004

Usage: With optimization, you can optimize the production dates/sequencing and resource
assignment of existing operations/activities that were previously created by production planning
runs or manual planning. The optimizer therefore does not delete or create orders.

The aim of optimization is to create executable production plans and increase efficiency in
production. Several optimization parameters (such as setup times and violations of due dates) can be
weighted for this so that the optimized schedule is as close as possible to achieving the required
result (for example, minimum setup times). The following parameters can be considered in detail in
optimization:
• Total lead time (start of first operation until the end of the last operation in a schedule within the
optimizing horizon). The total lead time indicates the compactness of orders within the
optimization horizon.
• Total setup times
• Total setup costs
• Maximum delay costs (maximum delay of an order with regard to its requirement date or due
date).
• Total delay costs (delay with regard to requirements or due dates)
• Total mode costs of alternative modes
© SAP AG
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Exercises
Unit:
Capacity Evaluation
Topic: Standard Overview
At the conclusion of these exercises, you will be able to:
• Use the standard overview in the capacity evaluation
• Change the displays
As a capacity planner in your company, you must compare the
capacity requirements with the available capacity in an overview.
To do this, choose the standard overview in the capacity
evaluation and switch to cumulate over periods if necessary.
1-1
Use your capacity planner group R## in the standard overview to look at the
capacity loads for your work centers.
Logistics → Production → Capacity Planning → Evaluation → Work Center
View → Load
1-1-1 In which evaluation period were the capacity requirements read?
Settings → General
1-1-2 Change the settings in such a way that only those periods with a load greater
than 80% are displayed.
Settings → Evaluations → Standard overview
1-2
Now call up the standard overview for the work center R-E##.
1-2-1 Change the display for the standard overview by defining a period as three
days.
Settings → General and then select Day and 3 as the Duration
1-2-2 Change back to the Week period display and set the indicator for Cumulate
over periods. Analyze the new standard overview for the entire evaluation
period.
Settings → General
Cumulate over periods
1-2-3 Only analyze the pegged requirements in the first period with capacity
requirements. What sort of pegged requirements are there?
Select the first period and choose Cap. details/period.
© SAP AG
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Exercises
Unit:
Capacity Evaluation
Topic: Detailed Capacity List
At the conclusion of these exercises, you will be able to:
• Use the detailed capacity list in the capacity evaluation
• Test different selection options
• Make changes to the detailed capacity list
As a capacity planner in your company, you want to view the
pegged capacity requirements for the work centers that you are
responsible for in an overview. After you obtain an overview,
you want to release a production order for production.
1-3
To release a production order, first convert the planned orders from the planning
run into production orders. Use the stock/requirements list and convert the first
three planned orders for material R-F1## into production orders.
Logistics → Production → MRP → Evaluations → Stock/Requirements List
By double-clicking on a planned order, you will see the “Details of MRP element”
screen. Choose ->Prod.Order and save the production order.
Repeat this process three times.
1-4
Call up the detailed capacity list in the capacity evaluation for your R-L## and RV## work centers.
Logistics → Production → Capacity Planning → Evaluation → Work Center
View → Orders
1-4-1 You want to call up the detailed capacity list for two special work centers.
To do this, you require an additional menu path. Enter the second work
center on the screen.
Planning → Selection → Work center
© SAP AG
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1-5
You want to know which production orders have been released. Before the order is
released you therefore copy the “Order status” field into the detailed capacity list
after the pegged requirements column.
1-5-1 Call the detailed capacity list again for your work centers
R-L## and R-V##. Now include a column for the “Order status” after the
pegged requirements column. Limit the column width for “Material” to 8
characters.
Do not save the changes to this detailed capacity list because the standard
list is changed in Customizing in this example.
Select “Choose fields ”.
Select “Order status” and copy it to the “Selected fields” list.
Select “Order status” and place the cursor on the line “Material”. Press
Move.
Change the column width for Material to 8 characters.
1-5-2 Release the first scheduled production order and update the evaluation so
that you can see the status change directly in the detailed capacity list.
Double-click the order number and in the order header, select Release and
Save. On the detailed capacity list, choose Refresh.
© SAP AG
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Exercises
Unit:
Course Overview
Topic:
Creating Capacity Requirements and
Reporting for APO
At the conclusion of these exercises:
• You will have created capacity requirements for capacity
planning in APO.
• You will be able to use capacity evaluation in APO.
• You will be able to change the displays.
As a capacity planner in your company, you should adhere to the
capacity requirement dates created in planning. Production
planning has various types of reporting that you can use to
analyze planning and planning problems.
1-1
Create a demand plan for the T-F3## and T-F4## products.
Advanced Planning and Optimization → Demand Planning → Planning →
Interactive Demand Planning
1-1-1 On the initial screen, Interactive Demand Planning, choose the Selection
window button to access the Object Selection dialog screen. Enter the APO
product in the first input field. Set the APO planning version, APO product
and APO location conditions. In these input fields, enter the active planning
version 000 and the products T-F3## and T-F4## for location 1000. Save
the object selection with the selection description GR##. Confirm the
selection with Enter.
1-1-2 Copy your selection ID to the selection profile.
Choose Maintain selection profile.
1-1-3 On the correction line in the planning table, enter 50 units in the third week
for the T-F3## product, and then enter 15 units in the second week, 40 units
in the third week and 30 units in the fourth week for the T-F4## product.
Save the planning quantities for both products.
© SAP AG
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1-2
Release the demand plan for the T-F3## and T-F4## products to production
planning. To do this, use the SCM260_000 variant and change the following
settings:
Period
From – date:
First day of the current month
To – date:
Last day of the next month
In the Object selection, select Multiple Selection to use the products for your
group number.
Advanced Planning and Optimization → Demand Planning → Planning →
Release to Supply Network Planning
Choose Get Variant.
Change the period and object selection before carrying out the release to SNP.
1-3
Execute a production planning run with the SCM260_001 variant for the production
planner 0##.
SAP Menu → Production Planning → Automated Production Planning and
Optimization → Production Planning Run
Choose Get Variant.
Use the Select.Crit. button to limit the production run to production planner 0##.
Save your settings as a variant with the variant name GR0## and the description
Planning 0##.
Choose Execute.
1-4
For your capacity planner group 0##, now look at the capacity requirements in
APO.
SAP Menu → Production Planning → Reporting → Order and Resource
Reporting
1-4-1 On the initial screen of planning version 000, enter the
time profile SCM260_000 and select Resource Utilization under Evaluation
List. On the following screen, enter your planner group 0## and select
Week under Period Selection.
1-5
Create a planned independent requirement of 30 pumps for the T-F2## product and
a delivery date of four weeks today.
SAP Menu → Production Planning → Product view
Choose Change.
Copy the default propagation range SAPALL.
Enter the requirements date and a receipt quantity of minus 30. Choose Save.
© SAP AG
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1-6
Execute an additional production planning run for the production planner 0## with
the selection variant GR##.
SAP Menu → Production Planning → Automated Production Planning and
Optimization → Production Planning Run
Choose Get Variant and then Execute.
1-7
Use your capacity planner group 0## to look at the capacity evaluations for your
resources.
SAP Menu → Production Planning → Reporting → Order and Resource
Reporting
1-7-1 First look at the Operation List in the active planning version 000 with the
evaluation start at the first of the month, and the evaluation end from today
to 3 weeks time.
Enter planning version 000 and the evaluation period. Select Operation
List.
On the dialog screen, enter 1000 in the Location field and enter your
planner group 0## in the Planner field.
1-7-2 Use the same selection options and look at WIP List (Network) in the
evaluation list.
Copy planning version 000 and the evaluation period from the previous
exercise. Select WIP List (Network) and confirm the selection data in the
dialog box.
1-8
Now call the list for Resource Utilization for your area of responsibility with Day
as the period selection.
Copy planning version 000 and the evaluation period from the exercises above and
select Resource Utilization. In the “Resource and period selection” dialog box,
enter Location 1000 and Planner 0##. Select Day as the period.
1-8-1 Now look for resources with overloads. For a clearer overview, change the
list displayed so that the Capacity Requirement, Resource Load in % and
Capacity Overload columns are displayed in the columns after the
available capacity. Save the changed layout, both for your user and as a
default setting, under GR-## with the name Group ##.
Press Change Layout and on the “Change layout” dialog screen, move the
Capacity Requirement, Resource Load in % and Capacity Overload
columns to the columns after the available capacity.
Choose Save Layout.
1-8-2 Only display periods with overloads and see which orders have caused this
overload.
Choose Set Filter.
From the list of columns, choose “Resource Load in %” and enter the
values 100 to 999 as the filter criteria. You can double-click to display the
orders.
1-8-3 Save the layout with the set filters as the new layout GR100-## and enter
Overload ## as the description.
© SAP AG
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Choose Save Layout.
© SAP AG
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Exercises
Unit:
Capacity Leveling
Topic:
Planning Strategies (APO)
At the conclusion of these exercises, you will be able to:
• Use the detailed scheduling planning board to execute
different planning strategies in capacity leveling
As a capacity planner, you have the task of executing detailed
scheduling on the critical resources of finished products. It may
be possible to move requirements that were already checked for
available capacity and then scheduled. It may also be necessary to
insert new requirements that have been scheduled at a later date
in a resource utilization without gaps.
1-1
Use the production process model to gain an overview of the production of pump
T-F4## in location 1000.
Master Data → Production Process Model → Production Process Model
Press Choose plan through PPM.
1-1-1 Display the Production Process Model (PPM). Select it with product
number T-F4## and location 1000. Press Display to enter the PPM.
The PPM is displayed in three screen areas. You are using the upper left
screen area and choose Functions to change to the resource list. Note the
resources on which the operations are executed:
© SAP AG
Resource WT-
_1000_00
WT-
_1000_00
WT-
_1000_00
WT-
_1000_00
WT-
_1000_00
WT-
_1000_00
WT-
_1000_00
WT-
_1000_00
WT-
_1000_00
TSCM32
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1-2
Look at the resources on which the production of pump T-F4## takes place.
Master Data → Resource
1-2-1 Select these resources after calling the transaction Resource in the following
way:
Location:
1000
Planner:
0##
This selection displays a row of single-mixed resources and multi-mixed
resources.
1-2-2 Note which resources in the PPM for the T-F4## product from the active
planning version 000 (see above) are single-mixed resources and multimixed resources, and establish how many individual capacities are
available for multi-resources (“Capacity” field on the Standard Capacity tab
page). Also check which resources are finite (“Finite capacity planning”
indicator on the Planning Parameters tab page).
1-3
Single/multi
No. of Cap.
Finite
WT-M##_1000_002
_________
_________
____
WT-V##_1000_002
_________
_________
____
WT-L##_1000_001
_________
_________
____
WT-L##_1000_002
_________
_________
____
WT-E##_1000_001
_________
_________
____
WT-E##_1000_002
_________
_________
____
WT-F##_1000_002
_________
_________
____
WT-P##_1000_001
_________
_________
____
WT-P##_1000_002
_________
_________
____
Execute several reschedulings with different strategies on the detailed scheduling
planning board with the PUMP_## overall profile.
Advanced Planning and Optimization ? Production Planning ?
Interactive Production Planning ? Detailed Scheduling Planning Board ?
Variable View
1-3-1 In capacity planning, you are only responsible for the resources of the
finished products, in other words, the pumps. Therefore restrict the view to
your resources in the work area.
In the work area, select the resource view and choose (Change) Set.
On the resource variant dialog screen, activate multiple selection to delete all of
the remaining resources as of the seventh resource. To confirm the changes, choose
Copy and Continue.
To save the change, choose (Save) Work Area.
© SAP AG
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1-3-2 With reporting, you determined that there was an overload on the resources
for your area of responsibility. Look at the planning situation for the WTL##_1000_001 and WT-L##_1000_002 resource. Describe the load
situation on these resources.
___________________________________________________
___________________________________________________
On the WT-L##_1000_001 resource in the resource chart, right-click the
Start with the first graphical object function and then select Resource
Utilization as Dialog Box ....
1-3-3 In the last exercise, you noticed an overload on the resource WTL##_1000_001. Execute a regenerative planning for this resource. Check
the result of regenerative planning by looking at the resource utilization.
Save the planning result and exit the planning board.
Select the resource and press Replan.
Extras → Resource Utilization → Display as Dialog Box
Choose Save and Copy.
1-4
The sales department has instructed that the last requirement for pumps for the
product T-F3## should be brought forward to a scheduling date of two weeks
today. You must ensure that the components are available.
To enable this rescheduling on all resources and components,
use the propagation range SAPALL.
.
Call up the detailed scheduling planning board again and choose the propagation
range SAPALL on the More Profiles tab page.
1-4-1 To carry out the rescheduling, set the strategy profile accordingly and save
the settings with your Customizing ID.
Define the strategy profile as follows:
Desired date: Entered date
General Strategy Parameters tab page, Infinite scheduling scheduling
mode, Forward planning direction
Strategy Parameters for Dependent Objects tab page, Always consider
fixed pegging and Consider within the propagation range dynamic
pegging.
Choose Save and Copy.
1-4-2 First look at the network display of the orders in the dialog box for the
order.
In the product chart of the planning board, navigate to the last order for the
pump T-F3##. Right-click to choose Expand multiple loading and Network
Display, Orders as Dialog Box.
1-4-3 Replan this order using the strategy defined in exercise 1-4-1 and a
scheduling date of two weeks today.
© SAP AG
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Select the order and choose Replan.
1-4-4 Look at the network display of the orders in the dialog box for the order and
check the rescheduling.
You have already learnt how to do this.
1-4-5 Bringing the order for the pump T-F3## forward (using infinite scheduling)
may have resulted in overloads on the resources. For all resources in the
resource chart, look at the resource utilization in the dialog box with Day as
the period selection.
Right-click to select all of the resources for the chart. Extras ? Reporting ?
Resource Utilization
Use your saved layout for overloads.
1-4-6 You want to level this overload on resource WT-L##_1000_001. Carry out
regenerative planning for this resource using the standard settings of the
SAP001strategy profile.
Choose Strategy. Delete the Customizing ID. Use the Refresh button to
restore the standard strategy.
Select the WT-L##_1000_001 resource and carry out regenerative planning.
1-4-7 Save the results of planning.
Choose Save and Copy.
1-5
Further planning strategies
Save the planning results from exercise 3-5 as a simulation
version, but do not do so until you reach 3-5-4.
.
1-5-1 After the third requirement, select all requirements on the WTL##_1000_001 resource and move these one week into the future. For a
better overview in the DS planning board, change to the month display.
To obtain the month view, press the right-hand mouse button on the date
line of the resource chart.
Select several requirements by using the left mouse button to drag the edge
of the frame while holding down the Shift key.
To move the requirements, also hold down the Shift key.
© SAP AG
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1-5-2
Look at the order for the first rescheduled operation. The lead time was
greatly extended as a result of the above rescheduling.
Right-click the Select objects for the same order function. Call up the
operation dates by double-clicking on the order and then on the operations
in the planned order.
1-5-3
Use drag and drop to move the first rescheduled operation, taking the
minimum lead time of the order into consideration. If the requirement on
the detailed scheduling board is too small, use the zoom function.
Change to the SAP001 strategy profile (without the Customizing ID) and on
the Strategy Parameters for Dependent Objects tab page in the strategy
profile, choose the For all rescheduled operations compact scheduling
strategy.
1-5-4 Look at the rescheduled order and save the planning result as simulation
version S##-1. To exit the planning board, choose Close without saving.
Choose Save.
On the dialog screen, enter S##-1 as the simulation version. To exit the
dialog screen, choose Save.
To call up simulation versions for processing or copying as
the active version, choose Production Planning →
Interactive Production Planning → Detailed Scheduling
Planning Board → Simulation Version.
.
© SAP AG
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Solutions
Unit:
Capacity Evaluation
Topic: Standard Overview and Detailed Capacity List
1-1
No solution is necessary, as all of the menu paths are in the exercises.
1-1-1
60 days as of today
1-2
No solution is necessary, as all of the menu paths are in the exercises.
1-3
No solution is necessary, as all of the menu paths are in the exercises.
1-4
No solution is necessary, as all of the menu paths are in the exercises.
1-5
No solution is necessary, as all of the menu paths are in the exercises.
© SAP AG
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Solutions
1-1
Unit:
Capacity Leveling
Topic:
Planning Strategies
No solution is necessary as all the menu paths are in the exercises.
1-1-1
0010: Resource
WT-M##_1000_002
0020: Resource
WT-V## _1000_002
0030: Resources
WT-L##_1000_001 Prim. Res.
WT-L##_1000_002
0040: Resources
WT-E##_1000_001 Prim. Res.
WT-E##_1000_002
0050: Resource
WT-F##_1000_002
0060: Resources
WT-P##_1000_001
WT-P##_1000_002 Prim. Res.
1-2
No solution is necessary as all the menu paths are in the exercises.
1-2-2
Single/multi
WT-M##_1000_002 Multi
2
WT-V##_1000_002 Multi
4
Finite
WT-L##_1000_001 Single
Yes
WT-L##_1000_002 Single
Yes
WT-E##_1000_001 Multi
3
Yes
WT-E##_1000_002 Multi
2
Yes
WT-F##_1000_002 Multi
2
WT-P##_1000_001 Multi
2
WT-P##_1000_002 Single
1-3
No. of Cap.
Yes
No solution is necessary as all the menu paths are in the exercises.
1-3-1
1. The resource does not have a schedule without gaps.
2. An overload due to multiple loading on the single resource exists.
1-4
No solution is necessary as all the menu paths are in the exercises.
1-5
No solution is necessary as all the menu paths are in the exercises.
© SAP AG
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Unit: Overview Solution Manager
 SAP AG 2004
© SAP AG
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OVERVIEW OF SAP SOLUTION MANAGER
Contents:
 Introduction to SAP Solution Manager
 Use in Implementations
 Use in Operations
 Additional Information
 SAP AG 2004
© SAP AG
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OVERVIEW OF SAP SOLUTION MANAGER:
Unit Objectives (1 of 2)
After completing this unit, you will be able to:
 Outline the key concepts and components of the
SAP Solution Manager
 Describe the key benefits of the SAP Solution
Manager and understand how the tools provided
support a successful and efficient SAP
implementation
 Relate by implementation phase how SAP Solution
Manager supports key activities
 Explain how SAP Solution Manager uses roadmaps
to guide implementation and operations activities
 SAP AG 2004
© SAP AG
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OVERVIEW OF SAP SOLUTION MANAGER:
Unit Objectives (2 of 2)
After completing this unit, you will be able to:
 Describe the business content delivered with SAP
Solution Manager
 Describe how the SAP Solution Manager supports
effective on-going management and continuous
improvement of the productive environment
 List key resources for additional information on the
SAP Solution Manager
 SAP AG 2004
© SAP AG
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OVERVIEW OF SAP SOLUTION MANAGER:
Business Scenario
 Your project team has been tasked with completing
an upgrade of all existing R/3 applications, in
conjunction with implementing all key CRM business
processes. You need to understand how the new
SAP Solution Manager toolset supports a successful
and efficient SAP implementation.
 You need to continue to support and optimize your
existing productive landscape.
 SAP AG 2004
© SAP AG
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Introduction to SAP Solution Manager:
Topic Objectives
After completing this topic, you will be able to:
 Outline the key concepts and components of the
SAP Solution Manager
 Describe the key benefits of the SAP Solution
Manager
 SAP AG 2004
© SAP AG
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Business Needs

Due to an ongoing spread of distributed systems and dependencies of business processes beyond
single system boundaries the need for a new efficient support infrastructure is required.

Integration aspects covering technical as well as business (applications) needs of these
heterogeneous environments are more crucial than ever and need to be mastered perfectly.

Software change management has to be taken into consideration including all aspects of single
component upgrade and release strategies as well as the development and the modification of
standard scenarios.

Minimization of potential risks during operations and early establishment of operation concepts is
the key in order to avoid unforeseen financial investments and to lower the operation cost to a
minimum.
© SAP AG
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Delivery of SAP Solution Management
SAP Solution
Management …
Global
Global
Strategy
Strategy and
and
Service
Service Level
Level
Management
Management
You
receive
delivered
through …
Business
Business
Process
Process
Management
Management
Safeguarding
Safeguarding
Managing technical risk and
ensuring technical robustness
of your solution
Management
Management
of
of mySAP
mySAP
Technology
Technology
Empowering
Empowering
Empowering your users with
core competencies to
implement and operate your
solution
Software
Software
Change
Change
Management
Management
Solution
Solution
Management
Management
Optimization
Optimization
Ensuring that your solution
works to its optimum
potential at all times
Support
Support Desk
Desk
Management
Management
Support Programs
 SAP AG 2004

Solution Management is the strategy and the SAP Solution Manager the technical infrastructure to
realize it.

The SAP Solution Manager brings in a new era of solution management covering all relevant aspects
for implementation, operations and continuous improvement.

The SAP Solution Manager as an integrated platform centrally running in a customer’s solution
landscape ensures the technical possibility to support distributed systems.

For further information regarding Solution Management refer to
http://service.sap.com/solutionmanagement & http://service.sap.com/solutionmanager
© SAP AG
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© SAP AG
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
Various implementation and operations roles are also delivered with the SAP Solution Manager.
Team members can log on using the roles and authorizations assigned to them and work through
their specific tasks.

The authorization concept for the SAP Solution Manager is predefined for the following roles:
 Project Manager
 Application Consultant
 Development Consultant
 Technical Consultant
 System Administrator
 Support Engineer
© SAP AG
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
SAP Solution Manager is a customer platform that enables representation and documentation of the
entire SAP solution.

SAP Solution Manager provides a single point of access into component systems for design,
configuration and testing activities.

SAP Solution Manager enables process-oriented design, configuration, testing and on-going system
monitoring during operations, regardless of the complexity of the system landscape.
© SAP AG
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
The SAP Solution Manager provides with the Business Process Repository central access to the list
of predefined business scenarios, which serve as a starting point for identifying the project scope to
be implemented.

When creating the detailed business blueprint, customers select the predefined business processes to
complement the project scope. In addition, the customer can create their own business processes.

The Business Process Repository is a package of reusable, predefined business process content
consisting of:
 Scenario documentation
 Transaction assignments
 IMG assignments
 Configuration guides
 Predefined test cases
Please note that the available Business Process Repository content may vary by scenario.
© SAP AG
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
In the Realization phase, the customer-specific solution defined during Business Blueprint is
configured and tested.

SAP Solution Manager enables process-oriented versus component-oriented configuration and
testing.

SAP Solution Manager provides a common platform for navigating to the various component
systems to complete configuration and testing activities.
© SAP AG
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SAP Solution Manager – Benefits at a Glance
 Benefits using SAP Solution Manager in Implementation








Central point of access and support for key implementation activities
Process-driven Blueprint, Configuration and Testing approach
Automated customizing synchronization across SAP components
Standard scenarios provided through the Business Process
Repository
Central repository to store project documentation and issues
Project monitoring / reporting capabilities
Services aligned to assure GoLive and smooth operations of the
customer solution
Benefits using SAP Solution Manager in Operations






Reduction of operational costs (TCO)
Customer satisfaction increasing performance
Service Level Management / Reporting
Application Management / Monitoring
Software Change Management for the entire solution
Best SAP Support with integrated Support Desk
 SAP AG 2004
© SAP AG
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Introduction to SAP Solution Manager:
Topic Summary
You should now be able to:
 Outline the key concepts and components of the
SAP Solution Manager
 Describe the key benefits of the SAP Solution
Manager
 SAP AG 2004
© SAP AG
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Use in Implementations: Topic Objectives
After completing this topic, you will be able to:
 Relate by implementation phase how SAP Solution
Manager supports key activities
 Explain how SAP Solution Manager uses roadmaps
to guide implementation and operations activities
 Describe the business content delivered with SAP
Solution Manager
 Outline how the tools provided can support a
successful and efficient SAP implementation
 SAP AG 2004
© SAP AG
TSCM32
12-16

The SAP Solution Manager is designed and structured to support you during all phases of your
implementation project. These phases are based on the 5 phases of the Implementation Roadmap:
Project Preparation  Business Blueprint  Realization  Final Preparation  Go Live &
Support

You can use the SAP Solution Manager to carry out the following activities during your
implementation project:
 Project Preparation: Define project and system landscape
 Business Blueprint: Identify customer-specific solution based on predefined scenarios in the
Business Process Repository and customer-defined business processes; Document business
processes
 Realization: Configure; Compare and distribute customizing; Setup test system; Organize tests
and perform

The SAP Solution Manager also supports cross-functions, such as:
 Reporting: Enables reporting at any point during your project to obtain information on the status
of your project and on the progress made, i.e. in blueprinting, configuration or testing.
 Roadmaps: To lead the implementation team through a project step by step; methodology and
supporting accelerators
© SAP AG
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SAP Solution Manager – Roadmaps at a Glance
Implementation methodology provided through Roadmaps



Implementation Roadmap

Target Group: Project Managers, Functional Implementation
Team (Application Consultants)

Milestone/sync points concept and support services aligned
Solution Management Roadmap

Target Group: Technical Implementation Team (Technical
Consultants) and Operations Team

Milestone/sync points concept and support services aligned
Global Template Roadmap


Target Group: Program / Project Managers
Global Roadmap content adapted to Solution Manager usage
 SAP AG 2004

Latest available Roadmaps are delivered with the Solution Manager. They contain the standard SAP
implementation methodology and cover the most important aspects and phases of a SAP
implementation.

A fundamental component of the Roadmaps is the links to accelerators and tools for performing the
tasks in a project.

The Roadmaps allow you to:
 Navigate in the structure
 Filter the structure items by role or subject area
 Display and assign documents
 Print individual documents or structures with assigned documents
 Search for specific items in the structure and accelerators
 Track status and create notes per structure item (e.g. for a work package)
 Create messages
© SAP AG
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Define Business Blueprint
1. Analyze and identify project structure based
on selected scenarios
- Evaluate process step by running transactions in
the related evaluation system
- Read SAP documentation
- Display related diagrams
2. Define your project scope
- Set structure items in scope that are part of the project
- Copy, Cut/Paste and rename project structure
- Add new structure items from library or create new items
- Set order in the structure to reflect the process flow
3. Describe your requirements in the Project
document tab that need to be supported
by the solution
- Use CI templates to document your process flow
and functional requirements
- Document your technical requirements
in terms of inferfaces, conversions, forms, reports
or other developments
 SAP AG 2004

Definition of the Business Blueprint allows you to document the business processes in your
enterprise that you want to use in your SAP System. You create a project structure in which relevant
business scenarios, business processes and process steps are organized in a hierarchical structure.
You can also create project documentation to assign to individual scenarios, processes or process
steps. To define how your business processes should run in your SAP Systems, you then assign
transactions to each process step.

Definition of the Business Blueprint provides you with a detailed description of your business
processes and system requirements. You can also print out the Business Blueprint document. The
project documentation and the project structure that you use during the Business Blueprint phase can
also be put to further use during configuration and test organization.
 When you configure your business processes, the system displays the project structure you created
for the Business Blueprint. You can use the Business Blueprint project structure as a point of
orientation during configuration.
 You can also display and edit the project documentation from the Business Blueprint phase during
configuration.
 The project structure from the Business Blueprint forms the basis for all test plans that you create
during test organization. The transactions that you assign to process steps in the Business
Blueprint are put in test plans during test plan generation. The transactions can be processed as
function tests to test the transactions.
© SAP AG
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
When creating the business blueprint, customers select the preconfigured business processes they
want to implement. Based on the scenarios selected to be in scope, the corresponding Business
Process Repository content is made available.

The Business Process Repository is a package of reusable, predefined business process content
consisting of:
 Scenario documentation
 Transaction assignments
 IMG assignments
 Configuration guides
 Preconfigured processes delivered via BC Sets
 Predefined test cases

Note: Latest available content for the Business Process Repository can be downloaded from
SAP Service Marketplace at http://service.sap.com/solutionmanager.
© SAP AG
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Realization: Process-Oriented Configuration
Re-useof
ofCustomizing
Customizingvia
via
Re-use
BCSets,
Sets,e.g.
e.g.ininaaRollout
Rolloutlocation
location
BC
Assigntest
testcases
cases
Assign
Customizingvia
viaIMG
IMG
Customizing
 SAP AG 2004

This project step configures the process requirements, specified in the Business Blueprint phase, in
the system.

SAP Solution Manager enables process-oriented versus component-oriented configuration and
testing.

SAP Solution Manager provides a common platform for navigating to the various component
systems to complete configuration and testing activities.

If you use objects from the Business Process Repository in your structures, they may already be
assigned to transactions and BC Sets.

If you create structures without objects from the Business Process Repository, you can assign
transactions yourself in the transaction Business Blueprint, and BC Sets, IMG objects and test cases
in the transaction Configuration.
© SAP AG
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Customizing Distribution – Typical Usage Scenarios
 Typical challenges / Usage Scenarios

Customizing of certain objects needs to be in sync across systems

Existing customizing (e.g. of SAP R/3) should be reused in other systems
(e.g. CRM)

Avoid redundant customizing activities within a Solution Landscape
(e.g. ALE scenarios)
 Distribution Scenarios

Delta Customizing





Distribution during customizing – at transport recording
Distribution at transport release
Periodic distribution
Manual distribution
Initial Customizing

Fast initial configuration of new development systems,
e.g. SAP CRM
 SAP AG 2004

You often have to synchronize selected customizing settings in various systems in a solution
landscape. You can use the Customizing Distribution to synchronize customizing settings in a source
system (e.g. SAP R/3) with the customizing settings in the target systems (e.g. an SAP CRM system)
in a SAP system landscape.

You use the Customizing Distribution to transfer customizing changes made in one SAP R/3
development system into other development systems in your system landscape. You can for example
use the Customizing Distribution to:
 Download selected customizing from an SAP R/3 system into a newly-installed SAP APO system
 Synchronize customizing in an HR and a non-HR system, and then use ALE distribution in a
stand-alone HR
 Synchronize customizing in an SAP R/3 system and an SAP CRM system, because you have
business processes which run in both SAP R/3 and SAP CRM

With the Customizing Distribution, you can perform the following functions on customizing settings
in a development landscape:
 Initial distribution from an SAP R/3 system into a target system
 Timed distribution
 Distribute automatically after each transport release or customizing change
 Distribute manually in a transport request
© SAP AG
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
You organize tests after you have created a Business Blueprint and made initial configurations in
the Realization phase.

This is the first step of the test organization in more detail: creating a test plan. During the Business
Blueprint phase, you have created a project structure, consisting of business scenarios, processes
and process steps. You have then assigned transactions and test cases to process steps. When you
create a test plan, the system will offer you exactly this project structure as a basis for your test
plans. In addition, the system will also provide all those manual and automated test cases you have
already assigned to processes or process steps, and you can select them for your test plan.
© SAP AG
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Procedure in Testing
 Create and assign test cases in transaction Configuration
(SOLAR02)
 Test organization (SOLAR03)




Test execution (STWB_WORK)





Access tester-specific worklist
Read test case and execute test in QAS systems
Track result and create message if required
Maintain status on test case in Solution Manager
Test monitoring & reporting



Systematic storage of test cases for testing business processes
(Sequence / Integration tests)
Administration of manual and automated tests
Generation of project-specific test plans and test packages
Detailed views of test progress and test results
Graphics and reports for all test plans in a project
Problem message handling


Administration of problems during testing
Detailed analysis and prioritizing of problems
 SAP AG 2004

The SAP Test Workbench functionality is reused in the Solution Manager Test Organization. For
further information about the Test Workbench, refer to the documentation in the R/3 System.
© SAP AG
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Document Management in the
SAP Solution Manager
KEY HIGHLIGHTS
 Central storage of all project documentation in SAP Knowledge
Warehouse (5.1) with main focus on Business Blueprint and
Configuration
 Provides functionality for creating, editing, storing, uploading and
downloading documentation (in SOLAR01/SOLAR02)
 Predefined templates / document types are shipped with SAP
Solution Manager:

Templates for scenario descriptions, diagrams and installation guides

Customer Input Templates (CITs)

Templates for interfaces, forms and reports
 Creation of project-specific documentation types (templates)
 Reporting features (by Assignment  Documents) allow you to
track and filter on all available documents
 SAP AG 2004
© SAP AG
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12-25
Use in Implementations: Topic Summary
You should now be able to:
 Relate by implementation phase how SAP Solution
Manager supports key activities
 Explain how SAP Solution Manager uses roadmaps
to guide implementation and operations activities
 Describe the business content delivered with SAP
Solution Manager
 Outline how the tools provided can support a
successful and efficient SAP implementation
 SAP AG 2004
© SAP AG
TSCM32
12-26
Use in Operations: Topic Objectives
After completing this topic, you will be able to:
 Outline how the SAP Solution Manager is a central
platform that supports effective on-going
management and continuous improvement of the
productive environment of a SAP solution
 Define the role the Solution Manager plays in SAP’s
service delivery infrastructure
 Describe how the SAP Solution Manager supports
process and system monitoring/reporting
 Explain how the SAP Solution Manager represents a
central platform for internal and external support
desk requirements
 SAP AG 2004
© SAP AG
TSCM32
12-27

SAP Solution Manager is the central navigation platform for key actitivities in operations.

SAP Solution Manager can monitor SAP solutions and SAP R/3 instances.

SAP software components can be monitored via RFCs or external agents at OS level. Non-SAP
software components can only be monitored via agents.

Several systems can be grouped together as a solution landscape and access to this landscape can be
restricted.

There is a remote connection to SAP that you can open for service delivery or expert help from SAP
Active Global Support.
© SAP AG
TSCM32
12-28
The SAP Solution Manager as the technical and operations infrastructure has different components:

OPERATIONS – Point of access to SAP Support Services, including Remote Services, On-site
Services, Self-Services, and Best Practice documents. Based on the solution configuration,
recommendations for these services are triggered dynamically. The reports resulting from each
service are available and are archived in the Operations section. The reports are useful
documentation stored in the SAP Solution Manager and serve as reference information for the
efficient future operation of the SAP solution landscape.

SOLUTION MONITORING – Covers solution monitoring, which instead of monitoring just
individual system components, monitors the business process across multiple components. Solution
monitoring involves systems monitoring, business process monitoring and service level management
to help monitor and administer the entire SAP solution.

SUPPORT – Offers a complete infrastructure for organizing and operating a solution-wide support
organization at the customer’s site. The Support Desk promotes effective user support in the SAP
solution landscape every step of the way – from the end-users to the internal support organization
and when necessary to SAP.
© SAP AG
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12-29

The idea of the SAP Solution Manager is to combine all aspects of SAP Service and Support
offerings (services, message handling, tools, knowledge products, ...) in one central portal and
facilitate the delivery.

The complete infrastructure of the Solution Management Strategy also includes the SAP Service
Marketplace. There are a couple of scenarios how this infrastructure can be used:
 Self Services: The Solution Manager enables customers to deliver Services themselves using
SAP’s proven technology and know-how.
 Remote Services: SAP Support can login into the customers’ Solution Manager system to deliver
a remote Service.
 Onsite Services: SAP Support or Consultants can use the Solution Manager to deliver Services
onsite. They can use the information stored in the Solution Manager and do not have to gather the
needed data each and every time.
 Search for Information or Services: Searching for information can be a challenging task –
especially if you have to consider many details to find the information, that exactly fits your
situation. If you use the Solution Manager to access the SAP Service Marketplace, you are
directed to the information that fits the data collected by the Solution Manager. Therefore you do
not have to dig through tons of information to get the piece that is currently relevant.
© SAP AG
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Solution Monitoring
Solution Monitoring is:

A proactive methodology

Business process oriented

Software solution landscape oriented

Configurable

Linked to expert analysis and administration tools

Open and extensible: Covers SAP R/3 as well as other SAP components

Linked to service procedures delivered by SAP
(EarlyWatch Service family, Optimization Services, Self Services)
Solution Monitoring consists of:

System Monitoring

Business Process Monitoring

Service Level Reporting
 SAP AG 2004
The monitoring section consists of:

Alert Monitoring – “Keep the business running” tasks (time schedule: hourly, daily)
 System Monitoring
 Business Process Monitoring

Service Level Management & Reporting – Continuous improvement, planning tasks (time schedule:
weekly, monthly)
 Service Level Reporting

The Goals of Solution Monitoring are:
 To detect critical situations as early as possible
 To enable the customer’s support organization to respond and resolve problems as fast as possible
© SAP AG
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Advanced Monitoring Features
Instances overview
Alert graphics
Alert overview
Analysis method
Open task overview
Task details
 SAP AG 2004

Real-time system monitoring and Central System Administration are work areas that complement
each other. You can control them both through the graphical displays of the SAP Solution Manager.

System monitoring alerts are shown at software component level. To display an alert overview, click
the alert icon. From the graphical interface, you can directly jump via RFC into the remote system to
start an analyses.

Examples – Monitoring and alert definition:
 R/3 background jobs
­ Start delay / End delay / Maximum processing time exceeded
­ Job cancelled
­ Incorrect parallel processing
­ Job log messages
 Transaction performance (effective from SAP R/3 Release 4.6)
­ Average dialog response time
 Update errors for transactions and programs
 Application log messages
 Due list log messages for deliveries and billings

Central System Administration: You can set up different administrative tasks (for example:
transaction su01, user maintenance) for your systems from a central point.
© SAP AG
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12-32
The Support Process
End
ser
End U
User
Creates Problem
Message
Solution
Solution
Support
Support
SAP
SAP Service
Service
Marketplace
Marketplace
2
1
mySAP
Enterprise
Portal
Search for
Solution
Provides Solution
SAP
Solution Manager
Find
Solution
or
Forward Problem
Message
4
Customer‘s
Notes Database
Provides Solution
Notes Database
Service Products
Best Practices DB
SAP
SAP Active
Active
Global
Global Support
Support
3
Provides Solution
Customer
Customer
SAP
SAP
 SAP AG 2004

The SAP Solution Manager enables collaboration from end-user support to SAP back office
resources. The SAP Support Desk lowers your solution management cost by setting up an efficient
internal and external support organization.

All SAP users can directly contact their support unit from within their daily work environment. Endusers in the satellite systems of your solution landscape can send support notifications into your
central Solution Manager system.

You see these notifications in the Support Notification Portal of the SAP Solution Manager. Relevant
system data (transaction code, Support Package level, and so on) are automatically copied into the
Support Notification.

The support employee can access this data and use advanced tools like:
 SAP Notes Search
 SAP Notes Assistant
 Workflow and e-mail notification
 Microsoft NetMeeting for application sharing
 Interface to SAP Service Marketplace to send Support Notifications to
SAP Active Global Support

SAP has enlarged the SAProuter interface so that customer Support Desk employees and SAP Active
Global Support employees can look at an end-user's desktop. To solve a problem, it can be important
to check the local desktop or frontend installations, for example to test an application direct from a
specific client.
© SAP AG
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Support Desk – Functions
 Customer internal message handling (Support Messages)



Messages created within the user's work environment

Automatic collection of system and context data

Third Party Message Interface
Manage SAP Notes efficiently

Integrated SAP Notes Search through the SAP Service Marketplace

Implement SAP Notes automatically with the SAP Note Assistant
Customer Solution Database



Build up your own solution database
SAP Support Integration

Send support message to SAP

Receive status updates and solution within Support Desk
SAP Remote Support Integration

Microsoft NetMeeting for application sharing between end users, SAP
Solution Manager power users and SAP Support back office experts
 SAP AG 2004

Basic Support Desk configuration on SAP Solution Manager running on SAP Web Application
Server 6.20:
 Create problem messages
 Search for SAP Notes
 Send error messages to SAP
 Receive an answer from SAP
 Implement SAP Notes with the SAP Note Assistant
 Basic functions that are delivered ready-to-run
© SAP AG
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12-34
Use in Operations: Topic Summary
You should now be able to:
 Outline how the SAP Solution Manager is a central
platform that supports effective on-going
management and continuous improvement of the
productive environment of a SAP solution
 Define the role the Solution Manager plays in SAP’s
service delivery infrastructure
 Describe how the SAP Solution Manager supports
process and system monitoring/reporting
 Explain how the SAP Solution Manager represents a
central platform for internal and external support
desk requirements
 SAP AG 2004
© SAP AG
TSCM32
12-35
Additional Information: Topic Objectives
After completing this topic, you will be able to:
 Detail the release strategy for SAP Solution Manager
 List resources for additional training opportunities
 List resources for additional information on the SAP
Solution Manager
 SAP AG 2004
© SAP AG
TSCM32
12-36

For additional information on the release schedule, please refer to the SAP Solution Manager
homepage, www.service.sap.com/solutionmanager.

Recommendations for our customers:
 New Installations:  2.2
 Existing Installations:  2.2 for advanced Business Process Monitoring and/or to support
implementation projects; Otherwise 2.1 is also feasible
 If advanced Support Desk functionality is needed: apply for Solution Manager 3.1 – Ramp-Up
 Unrestricted shipment of SAP Solution Manager 3.1 (GA release) is planned for Q3/Q4 2003
© SAP AG
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Training Courses
 SMI310 – SAP Solution Manager:
Implementation Tools in Detail
 TSLM10 – SAP Solution Manager for Operations
 SAP AG 2004
© SAP AG
TSCM32
12-38
Additional Resources






 SAP AG 2002,
SAP Solution
Manager 1
 SAP
AG 2004
© SAP AG
SAP Solution Manager presentations and collateral
http://service.sap.com/solutionmanager
SAP Solution Manager – Online Help (on tool CD)
SAP Solution Manager – Installation Guide
(alias: instguides)
SAP Solution Manager – Learning Maps (alias: rkt-solman)
Important Links on SAPNet / Service Marketplace:
 SAP Solution Manager – Homepage:
http://service.sap.com/solutionmanager
 Ordering SAP Solution Manager:
http://service.sap.com/swcat
 SAP Solution Manager – StarterPack:
http://service.sap.com/servicecatalog
 Latest Implementation Roadmaps:
http://service.sap.com/roadmaps
 SAP Standard Support:
http://service.sap.com/maintenance
 SAP Support Services:
http://service.sap.com/supportservices
SAP Note (Release Strategy – Solution Manager): 039461
TSCM32
12-39
Additional Information: Topic Summary
You should now be able to:
 Detail the release strategy for SAP Solution Manager
 List resources for additional training opportunities
 List resources for additional information on the
SAP Solution Manager
 SAP AG 2004
© SAP AG
TSCM32
12-40
OVERVIEW OF SAP SOLUTION MANAGER:
Unit Summary (1 of 2)
You should now be able to:
 Outline the key concepts and components of the
SAP Solution Manager
 Describe the key benefits of the SAP Solution
Manager and understand how the tools provided
support a successful and efficient SAP
implementation
 Relate by implementation phase how SAP Solution
Manager supports key activities
 Explain how SAP Solution Manager uses roadmaps
to guide implementation and operations activities
 SAP AG 2004
© SAP AG
TSCM32
12-41
OVERVIEW OF SAP SOLUTION MANAGER:
Unit Summary (2 of 2)
You should now be able to:
 Describe the business content delivered with SAP
Solution Manager
 Describe how the SAP Solution Manager supports
effective on-going management and continuous
improvement of the productive environment
 List key resources for additional information on the
SAP Solution Manager
 SAP AG 2004
© SAP AG
TSCM32
12-42
Unit: Preparation of Certification
 SAP AG 2004
© SAP AG
TSCM32
13-1
Preparation of Certification
Contents:
 Information on SAP Consultant Certification
 Example Questions
 SAP AG 2004
© SAP AG
TSCM32
13-2
SAP Consultant Certification
Solution Consultant mySAP Supply Chain Management - Manufacturing
(2004)
Software components: SAP R/3 Enterprise, SAP SCM 4.0
Certification duration: 3 hours
Number of certification questions: 80 multiple choice questions
Required certifications for participation in this certification test: None
Recommended courses: TSCM20 (Planning/Manufacturing I), TSCM32 (Manufacturing II),
TSCM34 (Manufacturing III (Case Study))
Please note that you are not allowed to use any reference materials during the certification test
(no access to online documentation or to any SAP system).
The certification test Solution Consultant mySAP Supply Chain Management - Manufacturing
(2004) verifies the knowledge in the area of the mySAP Supply Chain Management solution
for the consultant profile Manufacturing. This certificate proves that the candidate has a basic
understanding within this consultant profile, and can implement this knowledge practically in
projects.
The certification test consists of questions from the areas specified below:
Topic Areas
1. SAP Overview +

mySAP.com

Navigation (system handling)
2. Supply Chain Planning Overview ++

Master Data and Transaction Data

Demand Planning

Demand Management (planning strategies)

Cross-Plant Planning (Supply Network Planning)

Material Requirements Planning (MRP)

Production Planning and Detailed Scheduling (PP/DS)
3. Supply Chain Manufacturing Overview +
© SAP AG
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
Order-Controlled Production with Production Orders

Order-Controlled Production with Process Orders

Project-Oriented Production

Repetitive Manufacturing

KANBAN
4. Master Data: Engineering/Design +

Overview: Engineering/Design

Material Master

Bills of Material

BOM Reporting Functions

Variants and Alternatives


5. Master Data: Work Scheduling +

Overview: Work Scheduling

Routings - Part I

Work Center

Engineering Workbench

Routings - Part II

Scheduling
6. Master Data Integration (SAP R/3-SAP APO) +

Overview: Master Data Integration

Architecture of Integration

Transfer of Master Data

SAP APO Master Data

© SAP AG
TSCM32
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7. Production Orders ++

Order Creation/Order Changing

Integration for Planning

Order Release

Printing Order Documents

Material Staging

Order Control

Confirmations

Goods Receipt

Settlement

Archiving, Deletion, Retrieval

Information Systems

Collective Orders

8. Repetitive Manufacturing ++

Master Data

Planning (line loading)

Material Staging

Backflush and Receipts

Evaluations
9. Capacity Planning +

Capacity Leveling (tabular, graphic, available capacity)

Capacity Evaluations
10. Solution Manager +

Solution Manager-Overview
11. Experiences from Implementations (Case Study or Project)* +

Setting Up Company Structures (organizational units in mySAP.com)

Integration and Dependencies
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* = In topic area 12, you will be tested on cross-topic implementation and integration issues.
Implementation and integration knowledge that refers to a specific area (such as production
orders) will be tested in the relevant topic (such as Production Planning).
Weighting Key in the Test:
+
= 1 - 10%
++ = 11 - 20%
+++
= over 20%
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Exercises
Example Questions for Certification Test
The following example Questions will give you an insight into the general aspects of
certification questions.
Question 1: Which of the following units belong to the master data of production orders?
Several answers are correct. Decide for each alternative.
A: Procurement type
( ) yes
( ) no
B: Activity type in work center
( ) yes
( ) no
C: Sales document item for the material
( ) yes
( ) no
D: The quantity of production resources / tools
( ) yes
( ) no
E: The MRP list for the material
( ) yes
( ) no
Question 2: Which of the following statements are correct for the topic of operations of an
order? Several answers are correct. Decide for each alternative.
A:
B:
C:
D:
E:
Productions resources/tools may be assigned to suboperations
( ) yes
( ) no
Lead time scheduling is always carried out on the level of operations
( ) yes
( ) no
An operation is a single step within the order
( ) yes
( ) no
Components may be assigned to an operation
( ) yes
( ) no
Components may be assigned to suboperations
( ) yes
( ) no
Question 3: Which statement is correct for the conversion of planned orders into production
orders? Please select the correct answer.
A:
Planned orders may be converted completely or partially
( ) yes
( ) no
B: Fixed planned orders are converted automatically by the system
( ) yes
( ) no
C: Planned orders can only be converted completely; a partial conversion is not possible
( ) yes
( ) no
D: The changes of a planned order by an simultaneous planning run during the conversion
do not impact the conversion
( ) yes
( ) no
Question 4: What is the name of the time period that is used to convert planned orders into
production orders automatically?
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_______________________________
Question 5: Which statement is correct considering the release of a production order when
using an SCM system? Please select the correct answer.
A:
B:
C:
D:
Release of an order is always carried out in APO
( ) yes
( ) no
Release of an order is always carried out in R/3
( ) yes
( ) no
Release of an order can be carried out in R/3 or APO
( ) yes
( ) no
Release of an order is carried out without any relation to a specific system
( ) yes
( ) no
Question 6: Which possibilities are there to carry out material staging for production orders?
Please decide for each answer.
A:
B:
C:
D:
E:
Methods of IM/MM warehousing
( ) yes
( ) no
Replenishment via KANBAN
( ) yes
( ) no
Picking
( ) yes
( ) no
Crate parts
( ) yes
( ) no
Release order parts
( ) yes
( ) no
Topic: Repetitive Manufacturing
Question 7: Which possibilities of line loading are provided by a system landscape containing
only R/3 (without using APO)?
Please decide for each answer.
A:
Automated line loading, combined with an automated capacity- and material
requirements planning.
( ) yes
( ) no
B:
Manual line loading based on dynamic alerts.
( ) yes
( ) no
C:
Automated line loading without capacity planning (only planning of quantities)
( ) yes
( ) no
D:
Line loading via quota arrangement
( ) yes
( ) no
E:
Manual line loading considering capacity load
( ) yes
( ) no
Question 8: What is the name of the heuristics for an automated line loading in repetitive
manufacturing that you can use within APO (no modification necessary)?
_________________________________
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Solutions
Example Questions for Certification Test
Topic: Production Orders
Question 1:
A:
correct
B:
correct
C:
incorrect
D:
correct
E:
incorrect
Question 2:
A:
incorrect
B:
correct
C:
correct
D:
correct
E:
incorrect
Question 3:
A:
correct
B:
incorrect
C:
incorrect
D:
incorrect
Question 4:
Opening period
Question 5:
A:
incorrect
B:
correct
C:
incorrect
D:
incorrect
Question 6:
A:
correct
B:
correct
C:
correct
D:
correct
E:
correct
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Question 7:
A:
incorrect
B:
incorrect
C:
correct
D:
correct
E:
correct
Question 8:
Wave algorithm or multiresource planning
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Review
Review Questions
mySAP SCM - Manufacturing
Note:
This is a list of possible review questions. We do not guarantee that the range of these questions
is sufficient preparation for the test. The list should be seen as a pure discussion basis for the
review day.
© SAP AG
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© SAP AG
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SAP Overview
1.
What does mySAP business suite mean?
2.
Explain the structure of the client/server architecture
Tools for Project Implementation (Solution Manager)
1.
What is the IMG?
2.
What does the Solution Manager provide?
Master Data
Organizational Structures
1.
What are the various organizational structures in the R/3 System?
2.
What is the relation between controlling area, company code, valuation area, plant and storage location
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Material Master
1.
What is the purpose of different material master views?
2.
What is the relationship between material master views and individual organizational structures?
3.
How does the industry sector influence the material master maintenance?
4.
How does the material type influence the material master maintenance?
5.
What is the difference between external and internal number assignment and how is it set up in Customizing?
6.
Which other factors can influence the selection of fields in the material master?
7.
How can MRP profile and forecast profile be used to optimize material master maintenance?
8.
How can a material master be reorganized (deleted/archived)?
9.
Which units of measure can affect processing in the material master (base unit of measure, production unit,
order unit, etc.)?
10. What is the material status used for and on which levels could it be maintained?
11. Review the usage of the following settings?
-
MRP group
-
MRP type
-
Reorder point
-
Planning time fence
-
MRP controller
-
Lot size
-
Procurement type
-
Special procurement type
-
Production storage location
-
Backflush flag
-
Stock determination group
-
Bulk material
-
Scheduling margin key
-
Safety stock
-
Strategy group
-
Consumption mode and consumption period
-
Availability checking group
-
Alternative selection flag
-
Dependent requirement flag for individual and collective requirements
-
Production scheduler
-
Production scheduling profile
-
Underdelivery/overdelivery tolerance
-
In-house production time (lot size dependent/independent)
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-
Valuation class
-
Price control indicator
-
Moving average price/standard price
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Bills of Material
1.
What is determined by BOM usage?
2.
What technical types of BOM are available?
3.
Can the technical type of a BOM be changed?
4.
During which processes will BOM usage and status be considered?
5.
When would it be useful to make use of a Group BOM?
6.
What is meant by area of validity and effectivity of a BOM?
7.
Which item categories are available and what are their specifications?
8.
What is a sub-item?
9.
Under which circumstances could a BOM be recursive and what the usage of the recursive indicator?
10. What is a Bulk material (planning, costing)?
11. What is the usage of the following BOM settings?
-
Explosion type
-
Relevant to production
-
Relevant to costing
-
Material provision indicator
-
Bulk material
-
Production storage location
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Work Centers
1.
What is a work center category?
2.
What data can be maintained on the various views (basic, default, capacity, scheduling, costing, etc.)?
3.
What is the purpose of a standard value key?
4.
What role does the operation control key play?
What does referencing mean?
5.
Why to use a work center hierarchy?
What is a pooled capacity?
6.
Analyze the usage of the following fields?
-
Backflush indicator
-
Capacity category
-
Formulas for determining capacity requirements
-
Rate of capacity utilization
-
Relevant to finite scheduling indicator
-
Overload
-
Formulas for scheduling
-
Location group (move time matrix)
-
Queue times (normal and minimum)
-
Cost center
-
Activity types
-
Formulas for costing
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Routings
1.
What does a routing define?
2.
How is a routing structured?
3.
What task list types are available in the R/3 System?
4.
What is a routing group and group counter?
5.
What is a routing sequence, and what types of sequence are available?
6.
What could be reasons to use sequences?
7.
What are the various options to assign materials to routings?
8.
Under which conditions would it make sense to assign components to operations?
9.
What is a reference operation set?
10. How could the lotsize-dependent inhouse production time be calculated and updated into the material master?
Production Resources/Tools
1.
What types of PRT are available?
2.
What is the relationship between PRTs and a routing/operation?
Engineering Change Management
1.
What are the objectives of Engineering Change Management?
2.
What is the significance of changes with a history?
3.
Which PP objects can be managed using Engineering Change Management?
4.
What is the purpose of an engineering change request/order?
5.
How is a change master record structured?
6.
What is a revision level compared to engineering change master?
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Other Issues
1.
Which scheduling options are available, and how do they differ from each other?
2.
Which time components are taken into account during scheduling?
3.
How are basic order dates determined?
4.
How are the scheduled dates determined?
5.
Which scheduling types are available in lead time scheduling?
6.
What role do reduction measures play in scheduling?
7.
What types of scrap can be maintained in PP basic data and how would they be considered during MRP
respectively scheduling?
8.
What is external processing, and what conditions must be fulfilled before external processing can take place?
9.
What are co-products?
Classification
1.
Explain tasks/goals of classification.
2.
Explain the relation of class, class type, characteristics, characteristic values and their specific purpose.
3.
What could be objects in classification and how could they be classified?
4.
Which options exist to find a class itself?
5.
What could be achieved by using the status management within classification?
6.
Which different types of object dependencies exist?
7.
Describe the function of those different dependency types.
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Repetitive Manufacturing
General Issues
1.
What are the differences between discrete manufacturing and repetitive manufacturing?
Master Data for Make-To-Stock Repetitive Manufacturing
1.
What master data are necessary in repetitive manufacturing (material master, bill of material, production line,
routing)?
2.
Describe the the following material master data:
-
Repetitive manufacturing indicator?
-
Production versions?
3.
Which object is used to collect the material costs and production activities?
4.
What are the various options available for establishing a link between the cost collector and the production
version of a material?
Planning Repetitive Manufacturing in SAP R/3
1.
What is the purpose of the planning table in repetitive manufacturing? What functions can be executed from
here?
Material Staging
1.
Describe the usage of pull list and stock determination as one of its function.
2.
Which other logics are available to make sure that sufficient components are provided to the shop floor?
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Backflush
1.
What does backflush mean in a repetitive manufacturing context?
2.
Explain the functions of final backflush.
3.
How will the system react when a final backflush posting is cancelled?
4.
How can production activities be entered in the system?
5.
What is meant by post processing list?
6.
What are the advantages and disadvantages of negative stock?
7.
What does the reporting point backflush procedure entail?
Evaluations
1.
Which evaluations are available?
2.
What is a reporting point overview?
Production Order Processing
General Issues
1.
What are the characteristics of work-to-order production?
2.
What is defined in a production order?
3.
What is a document type, an order category and an order type?
4.
What are the various elements that a production order contains?
5.
Which functions are executed when an order is created?
6.
What are the various options available for creating an order?
7.
Describe the system logic during routing selection?
8.
Describe the system logic during BOM selection?
9.
At which point in time are reservations generated and what information does it contain?
10. What can be achieved by performing the “Read master data” function?
11. How could routing sequences be considered during production order creation?
12. Describe the conversion of planned orders into production orders with focus on scheduling aspects?
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Order Release
1.
What happens when an order is released?
2.
Which operations are made possible and which are prevented when an order is released?
3.
What is meant by status management?
4.
What are business transactions?
5.
What are the differences between system status and user status?
6.
At which points in time can availability checks be performed? Which settings can be made, and which must
be made? On which objects can the availability check be run?
7.
What is meant by machine commitment?
8.
What is meant by midpoint scheduling?
Printing
1.
Which shop floor papers can be printed?
2.
Which print modes are available (online, update, background)?
3.
What does “reprinting” mean?
4.
Which conditions must be fulfilled before order documents can be printed?
5.
Which conditions must an operation fulfill before shop floor papers (and in particular confirmation slips and
time tickets) can be printed?
Goods Issue
1.
Which control indicators influence the behavior of the components in the production order (bulk material,
backflush, phantom assembly, etc.)?
2.
What is meant by picking?
3.
What is meant by stock determination? Which settings have to be made for stock determination during
production order processing?
4.
What is a goods issue posting?
5.
How can goods issues be entered (reference to order, reference to reservation, unplanned, etc.)?
6.
What is the purpose of movement types?
7.
What are the effects of a goods issue posting from an integrational point of view (MM, FI, CO)?
8.
What is meant by the backflushing of components and how can this be achieved?
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Confirmation
1.
Which conditions must be fulfilled before confirmations can be entered?
2.
What is a confirmation?
3.
Which functions are linked to confirmations?
4.
Which confirmation procedures are available?
5.
What data can be entered during confirmations?
6.
What is a milestone confirmation?
7.
What is an unplanned milestone?
8.
What identifies a progress confirmation?
9.
What role does the control key defined in the operation play during confirmation?
10. Is it possible to link a confirmation with a goods movement posting?
11. What is a goods receipt?
12. What are the effects of a goods receipt posting?
13. What is the relevancy of the “delivery completed” indicator?
14. What is the function of overdelivery/underdelivery tolerance in the material master play?
Order Settlement / Archiving and Deleting
1.
What is meant by order settlement?
2.
Describe the individual steps during the logistical lifecycle of an production order and
3.
their integration to cost object controlling.
4.
What is the difference between prelimenary costing and actual costing?
5.
Which are the usual steps during order settlement?
6.
What means variance calculation?
7.
How is an order settled if the header material is a standard price material?
8.
At which points in time can an order be settled?
9.
Which conditions must be fulfilled before an order can be archived?
10. How are orders archived/deleted?
11. What is meant by “residence times”?
© SAP AG
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Order Information Systems
1.
Which information systems can be used for order management?
2.
What are the characteristics of the order information system?
3.
What are variable object overviews?
4.
What are the special characteristics of a (multi-level) order report?
5.
What is the difference between the order information system and the Shop Floor Information System?
6.
Which functions are available from the order progress report?
Automation Options
1.
What options are available for automating the processing of orders?
2.
What role does the production scheduling profile play?
3.
Describe the most lean production order and the necessary settings to achieve it?
4.
Which functions could be executed in the mass processing?
Collective Orders
1.
What are the characteristics of collective orders?
2.
How can collective orders be created? Which conditions must be fulfilled?
3.
What are the advantages of working with collective orders?
4.
Which functions can be performed on collective orders?
5.
How is scheduling for a complete collective order done?
6.
What happens if a date/quantity for an order is changed within the collective order?
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