SAP PP/QM
Configuration
INDEX
1.
OVER VIEW:-
4
2.
GETTING INTO THE CONFIGURATION AREA OF SAP
8
3.
MASTER DATA CONFIGURATION - BOM
12
3.1
Define BOM Usage
12
3.2
Define Default Values for item status
16
3.3
Define Allowed Material type for BOM Header
20
3.4
Define BOM Status
23
3.5
Define Item Category
26
3.6
Define Allowed item type for BOM Item
30
3.7
Define Explosion types
33
3.8
Define Order of Priority
36
3.9
Define Application
40
3.10
Define Alternative Determination for Multiple BOM
44
3.11
Alternative determination in related application Area
46
3.12
Define User-specific setting
47
4.
WORK CENTER
50
4.1
Define Work center Category
51
4.2
Define Field Selection
54
4.3
Define Task List usage
58
4.4
Define Parameters
61
4.5
Define Standard Value
65
4.6
Determine Person Responsible
69
4.7
Define Control Key
71
5.
CAPACITY PLANNING
76
5.1
Define Capacity Category
76
5.2
Determine Capacity Planner
78
5.3
Define Shift Sequence
81
5.4
Define Formula Parameters for Work centers
88
5.5
Define Formula for Work centers
91
5.6
Define Factory calendar
95
5.7
Define Default Capacity
106
5.8
Define Work center screen sequence
109
6.
ROUTING
112
6.1
Define Standard value description in operation over view
113
6.2
Define Routing Status
115
6.3
Define Task List usage
117
6.4
Define Reduction Strategy
119
6.5
Define User Fields
123
6.6
Define Routing Selection
7.
SUMMARY:-
Automatic
127
130
1. Over view:Production Planning module configuration
reports are demonstrated in this book.
and
relevant
PP module contains three types of manufacturing methods.
o Discrete
o Repetitive
o Process Industries.
Discrete: Discrete production method is applicable to the manufacturing
setup where small lots are manufactured with frequent
changes in the settings.
Manufacturing is accounted through Production orders.
Repetitive: This method is applicable, where products are manufactured
with least change or no change in the manufacturing process
over a long period of time.
Manufacturing is accounted through backflush.
Process Industries: It is similar to the Discrete but instead of routing, It uses
master recipe where in Process messages are maintained.
It is more appropriate to the food industries and processing
units where instructions are used during the process.
Manufacturing is accounted through process orders.
Configuration setting in PP module can be classified as below.
• Master Data related settings
• Planning Related Settings
• Production Execution related settings
We will discuss about the Master data related configuration
setting in detail.
Important Master data in PP module are
• Bill Of Material
• Work center
• Routing
Bill Of Material (BOM):BOM can be defined as “a list of required components along
with the required quantity essential to make any product”.
Important Technical details related to BOM are
Application of BOM
Usage of BOM
Status of BOM
Selection of BOM
Configuration setting related to BOM will enable to align the
BOM master data in line with the business requirement blue
print document.
Work Center:Machines, group of labour, processing unit are defined as
work center in SAP.
Work center contains the
Capacity Requirements
Scheduling details
Costing details
Configuration setting related to work center will enable to
define the SAP system according to the business requirement
blue print document.
Routing:Sequence of operation, work centers to be used and the
duration required for each operation to manufacture the
product is defined in routing.
Important Technical details related to Routing are
Usage of Routing
Status of Routing
Selection of Routing
Configuration settings related to Routing will enable to align
the Routing master data in line with the business requirement
blue print document.
Friends, the configuration settings related to each master data
are explained in detail.
Example:BOM
Item category configuration
Automatic alternate selection of BOM
Configuration of BOM usage
Configuration of allowed item type for BOM
Work Center
Configuration
Configuration
Configuration
Configuration
of
of
of
of
field selection in work center
formula to schedule and calculate cost
standard value key
shift sequence
of
of
of
of
Automatic Routing selection
Routing usage
reduction strategy
user defined fields in Routing
Routing
Configuration
Configuration
Configuration
Configuration
2. Getting into the Configuration area of SAP
BACKGROUND
To make the configuration in SAP, one has to have
authorization to perform transaction in configuration mode.
It is the place where every details are maintained to make the
transaction happen as per the business mapping.
SCENARIO
It is required to configure various settings in SAP.
INSTRUCTIONS
To do configuration, first one has to logon to the system, and
go to the IMG mode. How to logon to IMG mode is explained
below. From next document onwards, it is mentioned as IMG.
How to get in to the SAP IMG mode?
1. Type spro in the SAP main screen dialog box,
2. Click
3. Click on
Note:- Production related configurations are available under
Node.
4. Click
5. You are inside the IMG for Production Planning Module.
If the menu path is mentioned as “IMG” in the further
topics, you have to follow the above step to reach this place.
3. Master Data Configuration - BOM
3.1 Define BOM Usage
BACKGROUND
This configuration setting enables to define Bill Of Material
(BOM) usage.
BOM usage defines the usage of BOM in specific application
area in the SAP.
Example, there can be a separate BOMs for
Ø Design,
Ø Production
Ø Costing.
In this way, each area is dealing only with the specific data it
requires.
Example:
Ø The design BOM includes all the components of the
product and their technical data from the design point of
view. This BOM is generally not linked to any order.
Ø The production BOM contains all the items required from
the production and assembly point of view. Only items
relevant to production, for which production data (such
as the issue storage location) can be entered, are
required. A production BOM does not contain any
packaging materials required in the shipping department.
SCENARIO
Create new BOM usage.
Note:Standard BOM usage available with SAP is sufficient. However
any new BOM usage can be created.
INSTRUCTIONS
Follow the Menu Path: IMG → Production → Basic data → Bill
of materials → General data à BOM Usage à Define BOM
Usage
1. Click
2. Click
3. Enter usage value; it can be either numeric or alphabet.
It is suggested to be numeric.
4. Select +,- or . to indicate to which area this BOM is
meant for like Production, Engineering, Spare, Plant
Maintenance, Sales or for costing relevancy.
Note:-Based on this, during BOM explosion,
dependent requirements are also planned,
entire
5. Enter Usage text
6. Click Save
Impact of this configuration in Master Data /
Transaction
When creating the BOM, key defined here will appear in the
BOM Usage field.
According to the requirement, BOM usage key has to be
selected during BOM Creation.
Click Match code or
desired BOM usage.
F4 in BOM usage field, to select the
Transaction code to create BOM is CS01
3.2 Define Default Values for item status
BACKGROUND
This configuration setting enables to define default values for
item status.
Every item in the BOM can be defined whether it is subjected
to
Costing
Sales
Production
Spare part
This configuration setting is used to indicate whether the BOM
component along with the BOM usage.
Ø is to be considered for costing in this BOM or not,
Ø is relevant to sales (normally used in Variant
configuration),
Ø is a spare part
Ø is related to Production
SCENARIO
Set the default value for items in BOM.
INSTRUCTIONS
Follow the Menu Path: IMGàProductionàBasic dataàBill of
materialsàGeneral dataàBOM usageàDefine default values
for the item status
1. Click
2. Click
3. Enter Usage value
4. Update the following fields
Field Name
Description
BOM usage
Field defining the
BOM usage
Prod
Indicating that the
BOM item is related
to Production
Eng/des
Indicating that the
BOM item is related
to Engineering and
Design
PM
Indicating that the
BOM item is related
to
Plant
Value
Enter value e.g. 1
Make tick in the
check box
Leave blank.
Leave blank
Maintenance
Indicating the item
is related to Sales
and it will appear
in the sales order.
Relevant to costing
Sales
Relevan
5. Click Save
Leave
blank.
Normally used in
variant
configuration.
Select X , indicating
relevant to costing.
.
Impact of this configuration in Master Data /
Transaction
Example:BOM usage defined 1 indicating relevant to production. The
item status as configured such that all items
Ø are relevant to production
Ø can be relevant to costing
In this example, the indicators are checked as follows:
Ø The Indicator: item relevant to production cannot be
deselected (required entry). In the BOM maintenance
functions, this indicator is set automatically for all items
and cannot be cancelled.
Since the item can be relevant to costing, the default value
X (fully relevant to costing) can be set for the Indicator for
relevance to costing. This value can be overwritten in the
BOM maintenance functions.
BOM item level default setting will appear as per the setting
done here.
3.3 Define Allowed Material type for BOM Header
BACKGROUND
This configuration setting enables to control the creation of
BOM to the specific material types.
This configuration is done to the combination of BOM usage
and Material type.
When a new bill of material is created, the system checks the
material type as follows:
§ The fully qualified (non-generic) entries are checked first.
The generic entries are checked afterwards.
§ You can define that the use of the material type in
combination with Creation of BOM with respect to material
type can be controlled.
Example, it may not be allowed to create BOM for Raw
material. (Material type ROH).
Creation of BOM to material type ROH can be restricted in the
system.
SCENARIO
Creation of BOM for Material type ROH should not be allowed.
INSTRUCTIONS
Follow the Menu Path: IMGàProductionàBasic dataàBill of
materialsà General dataàDefine allowed material type for
BOM header
Click
Follow the below steps to create new entries.
1. Click
Update required and optional fields:
Field Name
BOM Usage ###
Material
header
Allowed
Description
BOM usage according
to the application
type Header Material type
to
which
BOM
creation has to be
restricted
Select
the
symbol
indicator to mention
allowed or not allowed
Value
1 for production
BOM
Enter ROH
Select
Negative
symbol
to
RESTRICT BOM
creation.
### Generic entry “*” can be made instead of a specific BOM
usage. This indicates, it is applicable to all possible BOM
usages.
2. Click Save
.
Impact of this configuration in Master Data /
Transaction
When a new bill of material is created, the system checks the
material type as follows:
§ Non-generic entries are checked first. The generic entries
are checked afterwards.
Error message will be displayed when creating BOM for RAW
material.
3.4 Define BOM Status
BACKGROUND
This configuration setting enables to define BOM status.
BOM status is used to define whether the BOM can be used by
any application area or not.
Example: Ø In the costing areas in a company, the BOM is exploded
according to the application. While defining the BOM
status, usage in costing area will be defined.
Ø In MRP, the following indicators are checked directly from
the definition of the BOM status:
- Explosion in MRP
- Released for orders
MRP only reads BOMs whose BOM status has at least one of
these indicators.
BOM status defines whether
The BOM is active or inactive.
SCENARIO
BOM need to be created for certain for product whose BOM
can be finalized only after some trial and error.
While it is in preparation it is required not to be used by any
application. Status “In preparation” has to be created.
INSTRUCTIONS
Follow the Menu Path: IMGàProductionàBasic dataàBill of
materialsà General dataàDefine BOM status
1. Click
…..continuation of the above screen’s right side balance
portion
2. Click
3. Enter usage value. E.g. 6.
4. Leave all the check box as EMPTY.
5. Mention description as “In preparation”
6. Click Save
.
Impact of this configuration in Master Data /
Transaction
BOM with status 6 can not be used for any application.
3.5 Define Item Category
BACKGROUND
This configuration setting enables to define item category.
The item category defines the attributes and functions of a
BOM item. It controls field and screen selection for detail
screens in BOM maintenance.
BOM can contain different type of items
manufacture the finished product. There are
related
to
Ø Pipeline items – i.e. items which are received
through a pipeline from supplier not related to
inventory
Ø Stock items – i.e. materials are always issued from
stock which are relate to inventory
Ø Document item – i.e. Documents are referred in the
BOM as a item trough the Document Management
System (DMS)
Ø Text item – i.e. brief note about the material usage
can be maintained as a Text item. This will be
useful in a long BOM to indicate any specific
assembly.
The above different items are defined through item category in
the BOM.
SCENARIO
Define item category to meet the situation as per the below
example.
Example: - An Item code may be defined as a normal item in
the material master. The same item code for one specific BOM
has to be treated as a phantom material.
In such a situation, item category inside the item detail of the
BOM will be mentioned as a phantom assembly. It is now
applicable only to this BOM.
Let’s look at the standard setting for item category.
Item categories defined by SAP will be sufficient in most of the
cases. If required, any new item category can be created.
INSTRUCTIONS
Follow the Menu Path: IMGàProductionàBasic dataàBill of
materialsà Item dataàDefine item category
1. Click
2. click
3. Update the following fields
Field Name
Item category
Description
Desired item category to be
mentioned in the BOM
Relevant
to
Inventory
management
It is text item
Variable size item
To mention Document
To mention as Class item,
used in Variant configuration
To mention as PM structure
element
To mention Intra Material
normally used in Master
Recipe-PPPI
Negative value allowed in the
BOM or not? This is required
to indicate the by product.
To indicate sub items are
supported.
Sequence of Item detail
screen.
Inv.Mgmt
TxtItem
Vsl
Document Item
Cls Item
PM Str
IntraM
+/- sign
SubI
Item Ctrl
4. Select check
requirement
boxes
according
5. Mention Item category Text
6. Click Save
.
to
the
business
Impact of this configuration in Master Data /
Transaction
While creating the BOM, required item category may be
selected.
3.6 Define Allowed item type for BOM Item
BACKGROUND
This configuration setting enables to control the item type
which can be entered as a component in the BOM.
Restriction to BOM item level can be done.
Example: - It may be required NOT to allow any Finished
Goods material type (FERT) to be a member of the BOM.
SCENARIO
It is required to restrict FERT material to be the member of the
BOM.
INSTRUCTIONS
Follow the Menu Path: IMGàProductionàBasic dataàBill of
materialsà Item dataàDefine allowed material type for BOM
items
1. Click
2. Click
3. Update the following fields
Field Name
BOM usage
Description
BOM usage to define the
application area
Mat tpe header
Header material type to which
this restriction is to be
applicable
Material type BOM Item type inside the BOM to
item
be restricted.
Allowed
+ sign to permit and –sign
NOT to permit
4. Click Save
.
Impact of this configuration in Master Data /
Transaction
While creating the BOM, only allowed component type in this
setting are allowed to be a member of the BOM item.
3.7 Define Explosion types
BACKGROUND
This configuration setting enables to define how the
component in Bill Of Material is to be exploded during
processing.
This configuration setting governs BOM Component
• To be considered for planning or not
• To be considered in Long Term Planning or not
• Phantom assembly is to be planned or not
• Direct production should be activated or not
SCENARIO
For Long term planning, by default all the BOM items are
considered.
If there are more items in a BOM and it is required to plan
only very specific items in the LTP.
Then at BOM level against the item, LTP off indicator can be
set. Now during LTP run, only relevant items are planned in
LTP and all items are planned in MRP run.
INSTRUCTIONS
Follow the Menu Path: IMGàProductionàBasic dataàBill of
materialsà Item dataàDefine Explosion types.
1. Click
Follow the below steps to create new entries.
2. Click
3. Update the following fields
Field Name
Description
Explosion type
BOM Explosion type, free
entry.
Description
Description of the Explosion
type key.
Phan.off
Plng off
DP Off
LTP Off
Indi/Coll
Phantom assembly is not
applicable to this item if this
indicator is set.
Material components are not
planned till the Sales order is
created to this BOM item if this
indicator is set
Direct production functions are
switched off if this indicator is
set.
This will exclude the item in
LTP calculation if this indicator
is set.
It is to specify, whether to
group
the
dependant
requirement together or not
4. Maintain the entries in the check box as per the
requirement
5. Click Save
Impact of this configuration in Master Data /
Transaction
BOM Item level explosion type can be defined. Key defined
here will appear in the screen to select.
3.8 Define Order of Priority
BACKGROUND
This configuration setting enables to define order of priority for
Bill Of Material to be selected during MRP and Production or
process order creation.
Different Bill Of Material can be created for
• Production
• Costing
• Engg / Design
Selection priority must be defined to pickup the right Bill Of
Material to the right application.
Link between this configuration
established as below:-
and
Master
Data
is
• Selection priority will be defined through selection id.
• Selection id will have the sequence of BOM usage.
• BOM usage will be mentioned in the BOM
• Selection id of BOM will be mentioned in the order type
and MRP plant Parameter.
SCENARIO
There are more than one BOM (BOM usage) They are
1 for Production,
2 for Engg/Design
3 for Costing.
It is required to define the order of selection for BOM.
INSTRUCTIONS
Follow the Menu Path: IMGàProductionàBasic dataàBill of
materialsà Alternative determinationàDefine order of priority
for BOM usage.
1. Click
Click
usage.
to create additional order of priority for BOM
2. Update the Following fields
Field
Description
Selection Id
Selection ID numeric
number to be entered.
Selection Priority
With in this selection
ID, priority to be
mentioned
BOM usage
With in this selection
ID
and
Priority,
relevant BOM usage to
be selected.
3. Click Save
.
Impact of this configuration in Master Data /
Transaction
During MRP run, production order or process order creation
BOM selected according to this selection id priority.
3.9 Define Application
BACKGROUND
This configuration setting enables to define BOM Application.
BOM application controls use of BOM in a specific area.
Areas like MRP run, cost estimate calculation etc.. will use the
BOM of its own respective BOM application.
SCENARIO
BOM display at multiple levels (transaction code CS12) can be
done for different BOM application. It is required to display
only the costing BOM to certain users. Separate BOM
application to be created to display the BOM related only to
costing.
Note: - BOM with usage for costing should be available. i.e.
with the right usage for costing.
INSTRUCTIONS
Follow the Menu Path: IMGàProductionàBasic dataàBill of
materialsà Alternative determinationàDefine Applications
1. Click
To view the details, select the line and click
2. Update the Following fields
Field
Description
BOM Application
Description
Selectin ID
Alternative Det.Multi.BOM
Production Version
MRP explosion
Rel planned orders
Release costing
Other check boxes
3. Click Save
Enter any four digit BOM
application area
Enter description
Selection ID through which
BOM selected
To select for alternative BOM
if multiple BOM is available.
Tick this check box
If there is a production
version, that is used as a
selection criteria.
Leave Blank
Leave Blank
Tick this check box
Leave Blank
.
Impact of this configuration in Master Data /
Transaction
When displaying the BOM through transaction code CS12,
Right BOM usage will be displayed according to the settings
maintained here. In this example, with BOM application, only
the costing BOM will be displayed.
Press F4 in BOM application, where all the available setting
will be displayed.
3.10 Define Alternative
Multiple BOM
Determination
for
BACKGROUND
This configuration setting enables to define automatic
selection of right Bill Of Material during MRP and production
order or process order creation, when there are more than one
Bill Of Material to a material.
SCENARIO
Specific alternative BOM for some materials are to be exploded
during the MRP and other production order process for
specific duration.
INSTRUCTIONS
Follow the Menu Path: IMGàProductionàBasic dataàBill of
materialsà Alternative determinationàDefine alternative
determination for multiple BOM.
1. Click
Follow the below steps to create new entries.
2. Update the Following fields
Field
Description
Material
Enter material code number
to which alternate BOM is to
be exploded
Plant
Plant where it is applicable
BOM Usg
BOM usage
Valid From
From date of BOM explosion
Alt BOM
Alternate BOM number which
is to be exploded.
3. Click Save
.
Impact of this configuration in Master Data /
Transaction
Right BOM according to the setting here will be exploded
during MRP and Production processing.
3.11 Alternative determination
application Area
in
related
BACKGROUND
Similar to the above alternate defining in production area, for
other areas like Inventory, MRP, Costing, Sales and
Distribution and Plant Maintenance can be maintained.
Only the menu path is given here and the rest of the settings
are similar to above.
INSTRUCTIONS
Follow the Menu Path: IMGàProductionàBasic dataàBill of
materialsà
Alternative
determinationàAlternate
determination in related application area
àDefine alternate determination for inventory
àProduction
àMRP
àCosting
àSales and distribution and
àPlant maintenance
3.12 Define User-specific setting
BACKGROUND
This configuration setting enables to configure the parameters
specific to the user.
Following parameters
Item category
Item increment
BOM Reporting specification are can be set for a specific
user.
INSTRUCTIONS
Follow the Menu Path: IMGàProductionàBasic dataàBill of
materialsà Define user-specific settings
Click
To view more details, select the required row and click
Click
to create new entries
Select the entries and tick the check box as shown above.
Field name
User
Item increment
Mat. Item cat.
Field value and description
Name of the user to whom the
default settings are to be
done.
While creating the BOM,
incremental number to be
displayed.
Item category to be displayed
by default.
While using the where used
list query, this check box in
the selection box will appear
as ticked by default.
While using the where used
list query, this check box in
the selection box will appear
as ticked by default.
Click
Impact of this configuration in Master Data /
Transaction
User SAPUSER when creating the BOM, this default setting
will appear. This will help to reduce BOM creation time.
4. Work Center
Machines may be referred as work center. It is defined as the
place where operations are carried out.
Apart from machine, group of persons (e.g. in maintenance
department, certain group of people may be employed for any
machinery movements etc.) may be treated as a labor work
center.
Data in work center used for
Ø Scheduling – start and end of operation
Ø Costing – Cost incurred during production
Ø Capacity planning - to plan the required capacity
Let’s see the configuration related to Work center.
4.1 Define Work center Category
BACKGROUND
This configuration setting enables to define work center
category.
Work center category is the major classification of work center
by SAP. E.g. Machine, processing unit, labor are defined as a
different work center category.
Work center category controls the field selection inside the
work center.
SCENARIO
Create a work center category to mention skilled labor work
center category.
INSTRUCTIONS
Follow the Menu Path: IMGàProductionàBasic dataàWork
centerà General Data àDefine work center category.
1. Click
2. Click
3. Update the Following fields
Field
Description
Cat
Capacity category. Any new
value may be entered. E.g.
ZLAB
Description
Description of the desired
capacity category. E.g. Skilled
Labour category
Field Selection
Contains the fields required to
this capacity category. Enter
standard SAP value according
to the capacity category. E.g.
0001
Screen sequence
Sequence of tab screen to be
appeared in the work center
master
data.
Enter
the
standard SAP value. E.g. 0001
4. Click Enter
5. Select Created capacity category
6. Double Click
7. Click
8. Enter Application – Area in SAP where this work center
category can be used. E.g. P – Routing; C - Master
Recipe; Q - Quality task list etc.
9. Note:- If this work center category is to be applicable to
all, maintain all the entry in this application field.
10.
Click
.
Impact of this configuration in Master Data /
Transaction
When creating the work center for skilled labor, work center
category is to be mentioned as it is a mandatory entry.
4.2 Define Field Selection
BACKGROUND
This configuration setting enables to make the field in work
center master data as
Mandatory
Optional
Highlight
Hide
Field selection will be used to make certain field as mandatory
entry or to hide certain fields during creation of work center
master data.
SCENARIO
Make field person responsible for work center category 0007
as mandatory field.
INSTRUCTIONS
Follow the Menu Path: IMGàProductionàBasic dataàWork
centerà General Data àDefine field selection.
1. Click
2. Double click Basic data
3. Double click Person responsible
4. Click Field selection Req. radio button for the required
work center category. Contents column indicate the work
center category.
Note:- From this screen it may be noted that person
responsible entry is mandatory for work center category
0001,0002 and 0008
5. Click
to add more entry.
6. Enter content 0007 or any work center category.
7. Click radio button Req.
8. Click
9. Click
Impact of this configuration in Master Data /
Transaction
When work center with category 0007 is created, person
responsible field become mandatory.
Note:- Field selection procedure is same for Routing as well.
4.3 Define Task List usage
BACKGROUND
This configuration setting enables to define the task list usage
to the work center.
Usage of work center specific to the task list (i.e. only in the
master recipe or Routing) can be defined to restrict its usage.
SCENARIO
Define the task list usage to the work center category 0007 to
be used in Routing and in Reference Operations set only.
INSTRUCTIONS
Follow the Menu Path: IMGàProductionàBasic dataàWork
centerà General Data àDefine task list usage.
1. Click
2. Select
3. Double click Task list type
4. Click
5. Update the Following fields
Field
Description
Task List type
N for Routing and S for
Reference Operation set
6. Click Save
.
Impact of this configuration in Master Data /
Transaction
When creating Work center usage is to be mentioned as 001.
Once this is maintained, then it will not be possible to use this
Work center in Master Recipe or in Rate routing.
4.4 Define Parameters
BACKGROUND
This configuration setting
(activities) for formula.
enables
to
define
Parameter
Parameter is one of the required settings to calculate the
conversion cost incurred in the Work center during
manufacturing.
Work center while in use can consume
• Power
• Labour
• Setup time
• Depreciation
• Steam etc.
The above costs incurred during conversion will be captured
through the activity. Parameter is the structure to capture this
activity.
This will be assigned to the standard value key. Standard
value key will be assigned in the work center.
SCENARIO
Create a Parameter. Note:- Standard SAP setting is sufficient.
Let us discuss the creation of new parameter.
INSTRUCTIONS
Follow the Menu Path: IMGàProductionàBasic dataàWork
centerà General Data àStandard ValueàDefine Parameters.
1. Click
2. Click
3. Update the Following fields
Field
Description
Parameter
Parameter to hold the value.
Any alphanumeric six digit
may be entered. E.g. LABOUR
Origin
Place where from the value is
to be taken. E.g. To indicate
value to be taken from task
list maintain 2 in this field.
Short key word
Short description
Key work
Key word to identify
Dimension
Dimension of the parameter.
E.g. Any thing related to
Duration may have TIME as
dimension.
Standard Value Unit
Unit of this parameter. E.g.
Time dimension may have
unit as MIN.
Note: - If any parameter for which there is no unit, it may be
mentioned as no unit.
4. Click Save
.
Impact of this configuration in Master Data /
Transaction
Link between the parameter and the master data is as below.
a. This parameter will be assigned to the standard value
key.
b. Standard value key will be attached with the work center.
c. Work center will be attached in the task list. I.e. in the
routing or in the master recipe.
d. Standard value (i.e. duration of labour hours required)
will be maintained in the task list as a master data.
4.5 Define Standard Value
BACKGROUND
This configuration setting enables to define the standard value
key.
Standard value key is very essential to capture the cost
incurred in the work center.
Standard value key will contain the activities. One standard
value key can contain up to six activities. Each activity refers
to the cost.
Example:• Production cost
• Set up cost
• Labour cost
• Quality Cost
• Power cost
• Steam cost
One work center can have only one standard value key.
SCENARIO
Create a standard value key to have the activities of setup,
machine, labor, and over head.
INSTRUCTIONS
Follow the Menu Path: IMGàProductionàBasic dataàWork
centerà General Data àStandard ValueàDefine standard
value key.
1. Click
2. Click
3. Update the Following fields
Field
Description
Standard value key
Enter any alpha numeric to
indicate standard value key.
E.g. STD1
Description
Maintain standard value key
description.
E.g.
setup/machine/labor/Power
Parameter
Maintain the parameters. Up
to six parameters can be
maintained.
Tick this check box to
generate formula.
4. Click Save
.
Impact of this configuration in Master Data /
Transaction
When creating the work center, standard value key STD1 to be
mentioned.
4.6 Determine Person Responsible
BACKGROUND
This configuration setting enables to define the person
responsible for work center.
Every work center will have a responsible person to schedule
the work load to that machine and to monitor the working
hours and output from that work center.
This field can be used for reporting purpose also.
SCENARIO
Create a work center responsible person.
INSTRUCTIONS
Follow the Menu Path: IMGàProductionàBasic dataàWork
centerà General Data àDetermine person responsible
Click
Click
Update the Following fields
Field
Plant
Person Responsible
Description
Name of the plant e.g. IND6
Three digit alpha numeric
entry
to
mention
the
responsible person to the
work center. E.g. INP
Person responsible description Detailed description of the
person responsible. E.g. Incharge Processing Unit
Click Save
.
Impact of this configuration in Master Data /
Transaction
When creating the work center, person responsible has to be
entered.
4.7 Define Control Key
BACKGROUND
This configuration setting enables to define control key.
Control key governs
• Scheduling of operation
• Cost calculation for an operation
• Capacity calculation for an operation
• Confirmation for an operation
Control key is mapped with the work center in the task list
(i.e. in the routing and in the master recipe).
SCENARIO
Create a control key with confirmation as mandatory and it
should calculate the cost and capacity, it should also schedule
the operation.
INSTRUCTIONS
Follow the Menu Path: IMGàProductionàBasic dataàWork
centerà Routing Dataà Define control key
1. Click
2. Click
3. Update the Following fields
Field
Description
Control Key
Enter any alphanumeric four digit
key. E.g. YP01
Description
Maintain description of this control
key.
E.g.
Sch/Cost/Capreq/Confreq/AutoGR
Indicators
Tick the check box as shown above
in the screen.
Tick in the Check box will perform
the respective function to the
operation / phase which is having
this control key.
4. Click Save
.
5. Click
control key.
to maintain any long text to this
6. Maintain the long text.
7. Click Save
.
8. Click
9. Click
10.
if you get the Other language screen.
Click Save
.
Impact of this configuration in Master Data /
Transaction
Link between control key and Transaction:Control key is attached in the task list with work center
for each operation
While performing order creation, confirmation, MRP run
system will behave according to this configuration
setting.
5. Capacity Planning
5.1 Define Capacity Category
BACKGROUND
This configuration setting enables to define the capacity
category.
Capacity category will differentiate the type of capacity used in
the work center.
Capacities can be
• Machine
• Labor
• Processing unit
Capacity category and capacity details are assigned to the
work center.
SCENARIO
Create a capacity category.
INSTRUCTIONS
Follow the Menu Path: IMGàProductionàBasic dataàWork
centerà Capacity Planningà Define capacity category
1. Click
2. Click
3. Update the Following fields
Field
Description
Category
Capacity category. E.g 001
Description
Description
of
capacity
category e.g. machine
4. Click Save
.
Impact of this configuration in Master Data /
Transaction
Capacity category is to be mentioned in the capacity header
detail in the work center.
5.2 Determine Capacity Planner
BACKGROUND
This configuration setting enables to define the capacity
planner.
Capacity planner is the person who is responsible to plan and
schedule the specified capacity.
SCENARIO
Create a capacity planner.
INSTRUCTIONS
Follow the Menu Path: IMGàProductionàBasic dataàWork
centerà Capacity Planningà Determine capacity planner
1. Click
2. Click
3. Update the Following fields
Field
Description
Planner
Enter capacity planner. E.g.
IN6
Enter
capacity
planner
description. E.g. Processing
unit plan
Description
4. Click Save
.
Impact of this configuration in Master Data /
Transaction
Capacity planner is to be mentioned in the capacity header
detail in the work center.
5.3 Define Shift Sequence
BACKGROUND
This configuration setting enables to define shift sequence.
Shift sequence is used to define the specific working pattern.
I.e. weekly holidays, number of shift and working hours of
each shift.
Work center capacity is calculated from its working hours
defined in the capacity header details of the work center.
There are mainly three ways to define capacity for each work
center.
• Normal capacity
• Available Interval capacity
• Interval and shifts
Normal capacity is defined through the working hrs and break
in the capacity header
Available interval capacity is the capacity available for any
specific duration; it is defined at the capacity header detail
Interval and shifts is defining the shifts in which the machine
or industry works.
SCENARIO
Create a shift sequence with two shifts a day and Thursday
and Friday as weekly holiday.
INSTRUCTIONS
Follow the Menu Path: IMGàProductionàBasic dataàWork
centerà Capacity Planningà Available capacityà Define shift
sequence
1. Click
2. Click
3. Update the Following fields
Field
Description
Grouping
Enter shifting grouping. E.g.
SG
Enter description E.g. Special
Grouping
Description
4. Click
two times
5. Select the Grouping
6. Double Click
7. Click
8. Update the Following fields
Field
Description
Break
Enter the Break name. E.g.
IN6B
Break Number
Enter the break number E.g. 1
Description
Description of break. E.g.
First shift break
Start
Break start time
End
Break end time
9. Click
above)
(Complete all the break required as explained
10.
Click
11.
Select the break 1 line
12.
Double click
13.
Click
14.
Update the Following fields
Field
Description
Shift
Enter shift name. E.g.1SHF
Shift text
Enter shift definition. E.g.
First shift
Starting date of the shift
End date of the shift
Starting time of the shift
End time of the shift
Enter the Break schedule. E.g.
IND6
Start date
End date
Start time
End Time
Break
15.
Click
16.
Select the 1SHT line
17.
Double click
18.
Click
19.
Update the Following fields
Field
Description
Sequence
Enter the sequence No. E.g.
01
Shift No.
Shift number in the sequence.
E.g. 1
Description
Description
of
the
shift
sequence. E.g. Two shift per
day
Day1 to Day 7
Maintain the desired shift
definition the day to follow.
E.g. 1SHT and 2SHT in all
days except Thursday and
Friday.
20.
Click
21.
Click Save
.
Impact of this configuration in Master Data /
Transaction
This shift sequence can be maintained as an interval of
available capacity.
This can be maintained in the work center capacity header
detail.
Once this is assigned, working days and hours to this work
center will be as per this shift sequence.
5.4 Define Formula Parameters for Work centers
BACKGROUND
This configuration setting enables to define the parameter for
the formula.
Formulas are to be defined to calculate
Cost
Capacity requirements
Schedule the operation
Formula parameter will be used in the formulas. Formulas are
used in the work center capacity view, scheduling view and
costing view to
Calculate capacity
Schedule the operation
Calculate the activity cost.
Note:This configuration is similar to defining the parameter
explained above. However it is reproduced for your quick
reference here also.
SCENARIO
Define formula parameter.
INSTRUCTIONS
Follow the Menu Path: IMGàProductionàBasic dataàWork
centerà Capacity Planningà Work center formulasà Define
formula parameter for work center
1. Click
2. Click
3. Update the Following fields
Field
Description
Parameter
Parameter to hold the value.
Any alphanumeric six digit
may be entered. E.g. LABOUR
Origin
Place where from the value is
to be taken. E.g. To indicate
value to be taken from task
list maintain 2 in this field.
Short key word
Short description
Key work
Key word to identify
Dimension
Dimension of the parameter.
E.g. Any thing related to
Duration may have TIME as
dimension.
Standard Value Unit
Unit of this parameter. E.g.
Time dimension
unit as MIN.
may
have
Note: - If any parameter for which there is no unit, it may be
mentioned as no unit.
4. Click Save
.
Impact of this configuration in Master Data /
Transaction
Formula parameter defined here will be used in the formulas.
5.5 Define Formula for Work centers
BACKGROUND
This configuration setting enables to define the formulas.
Formulas are used in
• Calculate capacity requirement
• Schedule the start and end of the operation
• Calculate the cost
Formulas will be assigned in the work center capacity view,
scheduling view and in costing view.
SCENARIO
Create the formula to calculate the machining time.
Note: - standard formula given by SAP will meet many
requirements. Let’s discuss the creation of formula.
INSTRUCTIONS
Follow the Menu Path: IMGàProductionàBasic dataàWork
centerà Capacity Planningà Work center formulasà Define
formula parameter for work center
1. Click
2. Click
3. Update the Following fields
Field
Description
Formula Key
Enter
formula
key.
E.g.
SAP002
Description of the formula key Enter description
Formula
Maintain the formula. Mostly
SAP defined formula would be
sufficient. Let us discuss the
SAP Standard formula and
understand
it.
Any
new
formula can be created similar
to it.
4. Parameter defined here are
SAP_02
SAP_09
SAP_08
SAP_11
Machine value from routing
Operation quantity- value from routing field
operation qty.
Base Quantity – value from routing field base
quantity
Operation split – value from routing field split
Above formula defined to calculate the machining time,
Machine time * Operation Quantity / Base quantity /
Operation Split
5. Indicators:Field name
Field description and value
Tick in this check box
indicates, this formula is
generated in the system.
Tick in this check box
indicates, this formula can be
used to calculate cost.
Tick in this check box
indicates, this formula can be
used to calculate capacity
requirements in MRP.
Tick in this check box
indicates, this formula can be
used
to
calculate
PRT
requirements.
Tick in this check box
indicates, this formula can be
used
for
scheduling
operations.
Impact of this configuration in Master Data /
Transaction
Formula is used in work center capacity, scheduling and
costing views.
5.6 Define Factory calendar
BACKGROUND
This configuration setting enables to define the Factory
calendar.
Factory calendar will contain the entire working day and
holiday details for a specific plant.
Factory calendar will be attached to the capacity header.
Factory calendar will be referred while scheduling the
operations.
SCENARIO
Define factory calendar for plant IND6.
INSTRUCTIONS
Follow the Menu Path: IMGàGeneral settings à Maintain
Calendar
Note: - Factory calendar will be defined directly in the client. It
will not be captured and transported through Transport
Management.
Click
First Holiday calendar has to be maintained. There are two
holiday calendar,
1.
2.
Public holidays
Specific Holiday calendar
Steps involved in Calendar maintenance are
• Create public holidays
• Create Holiday calendar and assign the public holiday in
the holiday calendar
• Create Factory calendar and assign the Holiday calendar
in the factory calendar.
Then the holiday calendar will be assigned to the factory
Calendar.
Let’s now maintain public holidays.
Select Radio button Public holidays
Click
Click
Select
Click
Click
Click
Create all public holiday by repeating the above explained
steps.
Click
Select
Click
Click
Enter calendar id. E.g. I6 to indicate it is for IND6 Plant
Enter description of the calendar. E.g. Holiday Calendar for
IND6 plant.
Enter valid from year and To year. E.g. From 2005 to 2025
Click
Select the required public holidays to be assigned to the
holiday calendar.
Click
Click
Note: - Whenever the calendar maintenance are saved, system
will give the message as shown above.
Click
Note: - To delete the assignment select the required holiday
and click
Click
Click
Click
two times
Click
Maintain the entry as above.
Click
Click
Click
three times to reach the main IMG menu.
5.7 Define Default Capacity
BACKGROUND
This configuration setting enables to define the default
capacity category for a plant.
By defining the default capacity, for work center and resource,
if the capacity is not defined, system will consider this default
capacity detail.
SCENARIO
Define default capacity category for plant IND6.
INSTRUCTIONS
Follow the Menu Path: IMGàProductionàBasic dataàWork
centerà Capacity Planningà Define default capacity
Click
Update the Following fields
Field
Plant
Category
Description
Enter the name of the plan.
E.g. IND6
Capacity category. E.g. 001
Click
Maintain the details as shown above.
Note: - this is the master data can be maintained inside the
each resource or work center in capacity header details.
5.8 Define Work center screen sequence
BACKGROUND
This configuration setting enables to define the screen
sequence for work center.
Screen sequence setting controls the sequence of appearance
of screen while creating the work center master data.
Work center contains the following important tab screens
• Basic view
• Default values
• Capacity
• Scheduling
• Costing
SCENARIO
Create a different screen sequence for work center category
ZLAB.
INSTRUCTIONS
Follow the Menu Path: IMGàProductionàBasic dataàWork
centerà Setup work center screen sequence
1. Click
2. Enter work center category ZLAB
3. Click
Field
No
Man
Description
Sequence number in which
tab
screens
are
to
be
displayed
Mandatory. Entry to be made
in this tab screen if this check
box is ticked.
Note: - Normally this setting is not at all disturbed, except
making some tab screen as mandatory.
Click
Impact of this configuration in Master Data /
Transaction
While creating the work center the sequence of Tab screen will
appear as per the configuration setting done here.
6. Routing
Routing explains how the product is to be manufactured. It
may be compared to a process sheet in the conventional
system. It contains
Ø Operations to be carried out during manufacturing
Ø Use of material during production
Ø Use of work centers
Ø Quality checks to be carried out during production
6.1 Define Standard value
operation over view
description
in
BACKGROUND
This configuration setting enables to define a key to hold the
standard text to be used in the routing operation.
If any common operation description is to be referred in the
task list (routing or in the master recipe), a standard key
containing the text can be used.
SCENARIO
Create a standard value key text for Routing.
INSTRUCTIONS
Follow
the
Menu
Path:
dataàRoutingà Control dataà
description in operation over view
IMGàProductionàBasic
Define standard value
1. Click
2. Enter task list type N for routing
3. Click
4. Click
5. Update the Following fields
Field
Description
Language
EN to denote English
1st SV Txt upto 6th SVTxt First standard value text up to
value
6th standard value text value.
Text entered will appear in the
routing operation.
6. Click Save
.
Impact of this configuration in Master Data /
Transaction
While confirming the operation these texts will appear against
the activity type.
6.2 Define Routing Status
BACKGROUND
This configuration setting enables to define the routing status.
Routing status helps to use the routing only for specified
purpose. I.e. Routing use can be restricted only for costing
purpose till the costing trial is completed.
Routing status can be
In Process
Released for costing only
Released for production
Selection of routing during production order or process order
creation is based on the routing selection.
Routing status has to be maintained in the routing header.
SCENARIO
Create a routing status.
INSTRUCTIONS
Follow
the
Menu
Path:
IMGàProductionàBasic
dataàRoutingà General dataà Define routing statuses
1. Click
2. Click
3. Update the Following fields
Field
Description
Status number
Enter numeric value
Description
Description of the status
number. E.g. Under creation,
or only for costing.
RelInd
Released Indicator, when this
is set, routing will be used in
Orders.
Costing
Indicates, task list is released
for costing.
Consistency Chk
Consistency check is carryout
automatically when saving.
4. Click Save
.
Impact of this configuration in Master Data /
Transaction
While creating the routing status is maintained.
6.3 Define Task List usage
BACKGROUND
This configuration setting enables to define task list usage.
Task list usage defines the specific purpose of routing.
There are four important usage of Routing.
• Production usage
• Costing only
• Sales and Distribution
• Universal ( all purpose)
It is possible to control the usage of routing according to its
usage.
SCENARIO
Define routing usage for multi purpose usage.
INSTRUCTIONS
Follow
the
Menu
Path:
IMGàProductionàBasic
dataàRoutingà General dataà Define routing usage
1. Click
2. Click
3. Update the Following fields
Field
Description
Usage
Enter the usage number. Any
numeric number. E.g. 1
Description
Description of the usage. E.g.
Universal
4. Click Save
.
Impact of this configuration in Master Data /
Transaction
Usage of Routing has to be mentioned while creating routing
6.4 Define Reduction Strategy
BACKGROUND
This configuration setting enables to define reduction strategy.
Reduction strategy defines the sequence of compressing the
time or duration to meet the production dates.
Reduction strategy can reduce the following times which are
involved in scheduling
• Queue time
• Move time
• Over lapping
• Split
Reduction strategy will be employed when the calculated lead
time in scheduling is longer than the time between the basic
dates (required start date and finish date is the basic date),
the system will carry out reduction measures to reduce the
lead time.
Reduction is carried out step by step. After each reduction
measure, the system checks whether the calculated dates are
within the basic dates. If this is the case, no further reduction
measures are carried out.
SCENARIO
Create a reduction strategy.
INSTRUCTIONS
Follow
the
Menu
Path:
IMGàProductionàBasic
dataàRoutingà Operation dataà Define reduction strategy
1. Click
2. Click
3. Update the Following fields
Field
Description
Plant
Enter the plant to which
reduction strategy is to be
created. E.g. IND6
Reduction strategy key
Any number to identify the
reduction strategy. E.g. 1
Reduction strategy
Description
of
Reduction
strategy.
E.g.
Over
al
reduction for IND6
4. Click
5. Select the Reduction strategy key entered above
6. Double click
7. Click
8. Update the Following fields
Field
Description
Re
Reduction Level. E.g. 1
Reduction Queue
Enter the % of reduction in
queue time
Transport
Tick the check box to indicate
the reduction in move time
Overlap
Tick the check box to indicate
the reduction in move time
Split
Tick the check box to indicate
the reduction in move time
Note: - Repeat the above step as different level as shown
below.
9. Click Save
.
Impact of this configuration in Master Data /
Transaction
This reduction strategy can be maintained in the Routing.
6.5 Define User Fields
BACKGROUND
This configuration setting enables to define user fields.
User field can be used in the operation heading in the task list
to define your own reference data.
Maximum of six fields can be defined through the user field.
SCENARIO
Create user defined field.
INSTRUCTIONS
Follow
the
Menu
Path:
IMGàProductionàBasic
dataàRoutingà Operation dataà Define user fields
1. Click
2. Click
3. Update the Following fields
Field
Description
Field Key
Enter the name of the field.
E.g. OPERDT
Description of the field key
Enter the description. E.g.
Operation detail user field
Maintain the text field as shown above
Impact of this configuration in Master Data /
Transaction
User field may be maintained at Routing operation header
level. Below screen shows the user field, where the details of
created by and other details can be maintained.
6.6 Define Routing Selection
Automatic
BACKGROUND
This configuration setting enables to configure the automatic
selection of routing (Task list).
Task list has to be selected automatically during
•
•
•
•
Production order creation (Routing)
Process order creation (Master recipe)
Cost estimate calculation
MRP run
Routing is essential to
• Calculate the conversion cost
• Calculate the capacity requirements
• Schedule the operation
• To schedule the material at right time in MRP
SCENARIO
Define Automatic routing selection.
INSTRUCTIONS
Follow
the
Menu
Path:
IMGàProductionàBasic
dataàRoutingà Routing selectionà Select automatically
1. Click
2. Click
3. Update the Following fields
Field
ID
Selection Priority
Task List type
Usage
Status
Description
Selection id. E.g. 01
Priority of selection in this ID.
E.g. enter from 1,2 …
Mention the task list type. E.g.
N for routing, 2 for master
recipe
Enter the Usage of this task
list. E.g. 1
Enter the status of this task
list. E.g. 4
Note: - Repeat the above with the same id as shown below.
Impact of this configuration in Master Data /
Transaction
In the order type dependant parameter and MRP plant
parameter configuration
Selection id 01 will be mentioned.
While performing the transaction (creation of process order or
production order or MRP run), automatic selection of routing
will be performed in the following sequence:
• First system will search task list type routing as per the
sequence 1
• System will search for routing with usage 1
• System will search for routing with status 4
If the above search fails, system will go to the next sequence in
the same selection id. I.e. sequence no. 2 in our above shown
screen shot.
• system will search task list type routing as per the
sequence 2
• System will search for routing with usage 1
• System will search for routing with status 2
7. Summary:We have discussed the Master data related configuration
settings.
You must be able to configure master data in SAP according to
the business requirement in the following areas
Bill Of Material
Work center
Routing
Friends, please note that the most of the configuration settings
related to master data are common to manufacturing types
Discrete
PPPI
Repetitive
The terminology only differs in the various processes.
For E.g. Routing is called as master recipe in PP-PI and in
repetitive routing is called as rate routing.
Discrete
PPPI
Repetitive
Routing
Master Recipe
Rate Routing
Work center
Resource
Production line