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Methods to Create a Production order / Process Order

The following are the methods through which a production order is created:

a) Planned order conversion: When a planned order (Planned order is created
through MRP or manually through MD11) is converted to an Order to execute the
production activities.

b) Order is created manually: When you create a Production order or process
order manually with reference to a material code or with reference to a reference to
a Sales order (in Process order there is no option to create with reference to a sales
order).


Production order creation transaction codes


Stock Requirement List Individual Display: MD04

Stock Requirement List Collective Display: MD07

Creation of Production order from planned order: Individual Conversion: C040

Creation of Production order from planned order: Collective Conversion: CO41

Creation of Production order from planned order: Partial Conversion: CO48

Creation of Production order from planned order: Individual Display Screen: MD13

Creation of Production order from planned order: Collective Display Screen: MD16

Creation of Production order using a material code: CO01

Creation of Production order using a sales order reference: CO08



Process order creation transaction codes


Stock Requirement List Individual Display: MD04

Stock Requirement List Collective Display: MD07

Creation of Process Order from planned order: Individual Conversion: C0R7

Creation of Process Order from planned order: Collective Conversion: COR8

Creation of Process Order from planned order: Partial Conversion: COR7_PC

Creation of Process Order from planned order: Individual Display Screen: MD13

Creation of Process Order from planned order: Collective Display Screen: MD16

Creation of Process Order using a material code: COR1



Creating a Production Order / Process Order in SAP

Creating a Production Order / Process Order in SAP

Following Text boxes, one by one, will explain SAP Production order / Process Order
creation


SAP Order Creation - Order Creation Selection Screen & Order Header Screen


Enter the following in the Order Creation Selection Screen


When you are converting a planned order to a SAP production/process order, there is
no necessity to enter anything on the selection screen. The selection screen entries are
required for entry if you are manually creating an order.





Material

Enter the Material for which you are creating a Production Order for


Production Plant

Enter the Plant code where the production order is to be created.


Planning Plant

This is the plant where order is executed and produced. If the production plant is equal
to planning plant there is no need to enter the planning plant.

If you wish to use the special procurements key like production in alternate plant, you
can use the planning plant as the plant where goods receipt is to take place and the
production plant is the plant where the actual production happens.


Order type

Order type is a like a document type against which you will be producing the order.
Order type contains a list of controls that decide how the order is to be created and
processed.

An order type decides the number range of the order, the method in which the
Routing/Recipes and/or the BOM is pulled in the order, documentation of order
information and goods movements, Batch determination search procedures, reservation
creation possibilities and the order costing controls.


Production / Process order number

If the Production order number and the process order number are defined for external
numbering, then in that case you need to provide a number up to 12 characters.


Copy from Option

SAP has provided options to copy from an existing Production order, when it does this it
creates one more order with the same order type, header material code and the same
plant. It copies the component list, the operation list and all the field values from the
reference order.



Enter the following in the Order Header Screen : General Tab


If you are converting a planned order to production order, the order is created with the
entire order header fields pre-populated (field values pulled in from the planned order)

If you are manually creating a production order, you would have to enter the values for
all the fields.






Total Quantity

Enter the quantity that is required for production. This quantity is inclusive of the scrap
quantity. The entered order quantity increases by the percentage of scrap entered in the
scrap field.

Any assembly scrap percentage maintained in the MRP1 View increases the total
quantity and enters a percentage and quantity in the scrap field. Assembly scrap allows
you to produce more than the ordered quantity to cover for scraps that may occur in the
production process during order execution.


Delivered Quantity

An amount is populated in this field, which is equal to the amount received in to stock
for the order.


Scheduling Types

Forward Scheduling: If Order Start date is entered, the Order Finish Date is derived by
the system.

Backward Scheduling: If Order Finish date is entered, the order Start Date is derived by
the system.

Current Date Scheduling: The System plans the order on todays date, both start and
finish date are todays date.

Only Capacity Requirement Scheduling: This option allows you to enter the start and
finish dates as you wish.


Schedule Margin Keys

The Schedule Margin Keys holds the Floats before and after production, the release
period given to the users to release the order from the order start date and the opening
period given to the users to convert the planned order to production order.

The floats in production increase the total lead time of production by adding the floats or
buffers to the lead time.


Order Dates/Times and scheduling types

When you are creating a production order from a planned order, the dates are borne in
from the planned order.

But if you are creating an order manually then these dates are calculated from the task
list (Routing/Recipe) pulled in the order. You can choose a scheduling type as required
(or have it preconfigured in the order type scheduling parameter)


Order Start and Finish date/time & Forward Scheduling

If an order start date is entered and Forward Scheduling is chosen, then the system
calculates the order finish date by adding up the Routing operations standard value
times (the system schedules forward in such cases).

Derivation of the dates based on Routing/Recipe is called lead time scheduling.

Forward scheduling is fit for use when you always have enough capacity available or in
the case of made-to-order when the customer is not so hesitant over the delivery dates
(in other words delivery dates are flexible)


Steps SAP Uses in Calculating the Dates :

Step 1: Enter the Order Basic Start Date

Step 2: Adds the Floats before Production to derive the Schedule Start Date

Step 3: Uses the Routing/Recipe for lead time scheduling to derive the Scheduled
Finish Date

Step 4: Add the Floats after Production to derive the Order Basic Finish Date


For example:

If there are 2 operations with some standard values as below and the order quantity is
15 Units:

Routing/Recipe Master Data:
Operation 0010: Casting: 1 HR/Unit
Operation 0020: Finishing and Packaging: 1HR/Unit

Therefore:
Total time at 0010 for executing the order : 1 HR X 15 Units = 15 HRS
Total time at 0020 for executing the order : 1 HR X 15 Units = 15 HRS

Schedule Margin Keys:
If Floats before production = 2 Days and Floats after production = 1 Days


Calculating Dates:
Enter Order Basic Start Date/Time as = 25
th
Dec 2010 (00:00 AM)
Add 2 Days as Floats before Production: 27
th
Dec 2010 (00:00 AM) which is
equal to = Order Scheduled Start Date/Time.
Derive the Order Scheduled Finish Date from Lead time forward scheduling
:28
th
Dec 2010 (06:00) as calculated below :
Add 1 Day of Floats after production : 29
th
Dec 2010 (06:00) = this is the Order
Basic Finish Date

Example illustration :

Operation
Number
Scheduled Operation Start Total Operation
Time

Scheduled Operation Finish
10 25
th
Dec 2010 (00:00) 15 HRS 25
th
Dec 2010 (15:00)
20 25
th
Dec 2010 (15:00) 15 HRS 26
th
Dec 2010 (06:00)

Order Basic
Start Date
Floats Order Scheduled
start date
Order Scheduled
Finish date
Floats Operation
Finish
25
th
Dec 2010
(00:00 AM)
2
Days
27
th
Dec 2010
(00:00 AM)
28
th
Dec 2010
(06:00)
1
Days
29
th
Dec 2010
(06:00)




Order Finish Date /time & Backward Scheduling


If an order finish date is entered and Backward Scheduling is chosen, then the system
calculates the order Start date by adding up the Routing operations standard value
times (the system schedules forward in such cases).

Backward scheduling is fit for use when you always have enough capacity constraints
or in the case of made-to-order when the customer is hesitant over the delivery dates (in
other words delivery dates are fixed)

Steps SAP Uses in Calculating the Dates :

Step 1: Enter the Order Basic Finish Date

Step 2: Subtract the Floats after Production to derive the Schedule Finish Date

Step 3: Use the Routing/Recipe for lead time scheduling to derive the Scheduled Start
Date

Step 4: Subtract the Floats before Production to derive the Order Basic Start Date


For example :

If there are 2 operations with some standard values as below and the order quantity is
15 Units:

Routing/Recipe Master Data:
Operation 0010: Casting: 1 HR/Unit
Operation 0020: Finishing and Packaging: 1HR/Unit

Therefore:
Total time at 0010 for executing the order: 1 HR X 15 Units = 15 HRS
Total time at 0020 for executing the order: 1 HR X 15 Units = 15 HRS

Schedule Margin Keys:
If Floats before production = 2 Days and Floats after production = 1 Days

Calculating Dates:
Enter Order Basic Finish Date/Time as = 29
th
Dec 2010 (06:00)
Subtract 1 Days as Floats after Production: 28
th
Dec 2010 (06:00 AM) which is
equal to = Order Scheduled Finish Date/Time.
Derive the Order Scheduled Start Date from Lead time forward scheduling: 27t
h

Dec 2010 (00:00) as calculated below.
Subtract 2 Day of Floats before production : 25th Dec 2010 (00:00 AM) = this is
the Order Basic Start Date


Operation
Number
Scheduled Operation
Start
Total Operation
Time

Scheduled Operation Finish
10 25
th
Dec 2010 (00:00) 15 HRS 25
th
Dec 2010 (15:00)
20 25
th
Dec 2010 (15:00) 15 HRS 26
th
Dec 2010 (06:00)


Order Basic
Start Date
Floats Order Scheduled
start date
Order Scheduled
Finish date
Floats Operation
Finish
25
th
Dec 2010
(00:00 AM)
2
Days
27
th
Dec 2010
(00:00 AM)
28
th
Dec 2010
(06:00)
1
Days
29
th
Dec 2010
(06:00)




Order Start/Finish Dates and Current Date Scheduling


When you do not enter any value for the order start date or orders finish date and
choose the scheduling type as Current Date Scheduling, the system enters the start
and finish dates as todays date.


Order Start/Finish Dates and Only Capacity Requirement Scheduling


When you choose to enter both the order start date and orders finish date manually
then in that case you should choose the scheduling type as Only Capacity
Requirement Scheduling.


Order Start/Finish Dates and Forward in Time Scheduling

If order start date/time both are entered and Forward in Time Scheduling is chosen,
then the system calculates the order finish date and time by adding up the Routing
operations standard value times (the system schedules forward in such cases).

The only difference here is that along with Order Start date you can also enter the order
start time and allow the system to calculate the order Finish date and time.


Order Start/Finish Dates and Backward in Time Scheduling

If order Finish date/time both are entered and Backward in Time Scheduling is chosen,
then the system calculates the order Start date and time by adding up the Routing
operations standard value times (the system schedules forward in such cases).

The only difference here is that along with Order Finish date you can also enter the
order finish time and allow the system to calculate the Order start date and time.


Scheduled Start Date

The Scheduled start date is always equal to the Basic Order start date, if floats dont
exists. But if you include schedule margin keys with a value of Floats before
production, the scheduled start date is calculated.


Scheduled Finish Date

The Scheduled Finish date is always equal to the Basic Order Finish date, if floats dont
exists. But if you include schedule margin keys with a value of Floats after production,
the scheduled finish date is calculated.



SAP Order Creation - Order Header Assignment Tab

Enter the following in the Order Header Screen: Assignment Tab


Not a Mandatory Tab for Data Entry: The fields in the assignment tab are not mandatory
for entry by a consultant or user while creating an order.






MRP Controller / Production Scheduler:


Automatically Pulled in: MRP Controller and the Production Scheduler is pulled in from
the header material master. MRP Controller is the person who plans and converts the
planned order in to production order.

If you havent maintained the data in the Material Master of the order material, then you
still have an opportunity to enter it right away in the order.

Supposedly, the job of the MRP controller ends there and the job of the Production
scheduler comes in.

The production scheduler is supposedly the person who manages the order and
executes it in the shop floor. A production scheduler can be the shop floor supervisor.

In many cases the MRP controller and the Production Scheduler is kept as the same.

Configuration: You can configure MRP controllers and Production Schedulers in
Transaction code OPPQ and OPJ9 respectively.


Production Plant / Planning Plant


The Production plant and the planning plant is brought in from the selection screen.


Sales order number / Sales order Line item


If you are in a Made-to-Order Scenario and the production order is created from a
requirement arising from Customer Sales order. You can trace the production order or
process order for the customer sales order, for its progress.

In a made-to-stock scenario there is no connection at all with the customer order or the
customer number. In a made-to-stock situation the production is carried out to stock and
supply from that stock to satisfy any incoming sales order.


Business area

The business area is determined via the division defined in the material master record.

An organizational unit of financial accounting that represents a separate area of
operations or responsibilities within an organization and to which value changes
recorded in Financial Accounting can be allocated.
You can create financial statements for business areas, and you can use these
statements for various internal reporting purposes.


Inspection lot

When you are carrying out inspection at GR from the order, an inspection lot is created
at goods receipt, this inspection lot is updated here.


Planned order

When you are using Material Requirement planning to plan the header material and a
planned order is created to cover the demand and subsequently converted to an order;
this planned order which is used to convert to this order is populated here.

The planned order once converted to production order is deleted from the system and
also removed from the tables. Thus if you try to see this planned order in MD12 or
MD13, you wont be able to see it.


Production Version

When the BOM and the Routing/Recipes are selected in the order from a valid material
production version, then that production version is populated in the order here.


Reservation Number

Once you create the order, even before releasing the order, the system creates a
reservation number for the order which contains the list of components (dependent
requirements) which would be used to manufacture the product. This reservation list
reserves these components for production.

Configuration: You have an option to use these reservations as hard reserving or soft
reserving through the scope of availability settings.

Normally the reservations on components are not hard reservations and these
components can be used across orders.

Uses of Reservations: Reservation list can be used by the warehouse or the materials
department to keep the components ready for production order or process order.
Subsequently the same reservation list can be used for staging the materials to the
shop floor for issue to the order.

Transaction code: You can see the reservation in MB23 (you cannot change
reservations created through an order).

Stock Overview: You can see a column in the MB52 or MMBE that suggests the total
quantity reserved for the material.



SAP Order Creation - Order Header Goods Receipt Tab

Enter the following in the Order Header Screen : Goods Receipt Tab


Not Mandatory Tab for Data Entry: This tab is not mandatory for entry by a consultant or
user to create an order.




Stock Type

Automatically populated: Stock type field specifies where the stock would be posted
when you create a goods receipt for the order through MB31 or MIGO transaction
codes.

If Quality management is active for the header material master and there is an
inspection type maintained in the material master to support inspection at goods receipt
from order, the proposed stock type in which case is Quality Inspection and if not, the
system would always propose unrestricted stock type (free for use stock type).

The default GR stock type is unrestricted stock type where the stock is free for use.

You can also decide to receive the goods into blocked stock (this can be done manually
in the production order).

Think over it: Though it is also possible that the GR storage location is designed to
book receipts into blocked stock only in which case, the goods will always be posted
into blocked stock, no matter what.


GR Processing time

It is pulled in from the MRP views of the Header Material Master


Goods Receipt Indicator / delivery Complete Indicator

Once GR is done for the order, the indicators are automatically updated.


Goods receipt Storage location

Automatically Updated: If you have included a Production storage location for the
header in the material master MRP 2 View, the same is populated here during order
creation.

The second option is to get the Production Storage Location from the Production
Version.

If there is no Storage location maintained in Material Master or the Production Version,
you can enter one directly here, though its not mandatory. In which case you will not
find any Storage location defaulted at the time of GR from Order, and you have an
opportunity to enter one there.


Batch

If you are creating a Batch Master for the header material at the order header level, i.e.,
all the goods receipts which will be created from the order will be mandatorily for this
batch.

Why do you create batch at header level : When you are damn sure that you will always
use only one batch to receive goods from an order, then you have an opportunity to fix
the batch number in the production order release or create mode itself. You can also
classify this batch with values which are required to be populated prior to production
start. The creation of batch at the header level may also be required in cases where the
product labels are printed prior to goods receipt and they require the batch number to
be on it.

Automatically created : This batch is automatically created when you create or release
the order. But if you want to overwrite it with another batch number you can certainly do
so.

Configuration required: For creating a batch at the header level, you have to use SPRO
transaction code CORW, where you can set-No automatic Batch creation, Automatic
Batch creation at order release or Automatic Batch creation at order create. At the same
time you can decide to have the batch classified in the order or not and if you decide to
classify the batch it can be either in the foreground (in the production order screen itself)
or in the background. Note that this configuration is done at a plant & production
Scheduler Profile level.



Order Delivery Tolerances


The tolerance value is automatically pulled in from the material master.

These are tolerances with which an order quantity can be received in stock or confirmed
in SAP.

If you maintain under-delivery tolerance: This means that the order can be received in
stock or confirmed with a quantity lesser than the order quantity as decided by the
under-delivery tolerance percentage entered in this field.

The final confirmations and the order GR only allows the quantity allowed by the under-
delivery tolerance. For example if the order quantity is 100 and the under-delivery
tolerance is 20%, then the system allows only 80 units to be confirmed in the
confirmation screen and once you reach 80 units a CNF status is assigned (fully
confirmed status) at the same time once you receive 80 units in GR, the system assigns
a fully delivered (DLV status) to the order and you can receive no more now.

If you maintain over-delivery tolerance: This means that the order can be received in
stock or confirmed with a quantity more than the order quantity as decided by the over-
delivery tolerance percentage entered in this field.
The final confirmations and the order GR only allows the quantity allowed by the over-
delivery tolerance. For example if the order quantity is 100 and the over-delivery
tolerance is 20%, then the system allows only 120 units to be confirmed in the
confirmation screen and once you reach 120 units a CNF status is assigned (fully
confirmed status) at the same time once you receive 120 units in GR, the system
assigns a fully delivered (DLV status) to the order and you can receive no more now.

If you maintain unlimited delivery: You can receive more or less than the quantity
required. This is very risky and must be used when the business is damn sure of what
they are doing. This can be a situation, when the organization does not know how much
more or less they might receive from the order (use this sensibly).




SAP Order Creation - Order Header Control Data Tab & Dates Tab

Enter the following in the Order Header Screen: Control Data Tab


Not mandatory for data entry: This tab is not mandatory for entry by a consultant or user
to create an order.


All the fields in this tab are brought in from order type dependent parameter
configuration or order type scheduling parameter configuration. You dont have to do
much here





Fields values pulled in from Order type dependent parameter configuration

Create Reservations/Purchase Requisition: Defining when the reservations and
purchase requisitions for non-stock material should be created.

Costing Variant Plan:

Costing Sheet ID:

RA key:

Planned Cost Calculations: determines when the planned cost should be created, to be
created at the point of saving or saving after release.

Costing Variant for Actual Costs:

Overhead Key:

Variance Key:


Fields values pulled in from Order type scheduling parameter configuration

The below configuration values are pulled in from the order type scheduling parameters
which is used to control the scheduling and capacity generation for the order.

Calculate Capacity Requirements: If this is selected, then the capacity requirements are
generated for each of the operations/work centers/resources in the order.

Exact Breaks: If this is selected, then Scheduling should consider breaks.

Schedule Automatically: This indicator is set at release, and it means that the order will
be scheduled at the time of saving the order, every time you make a change to the
operations details.


Production Scheduling Profile


The Production Scheduling contains a set of control for the production order, it is not
mandatory to maintain a scheduling profile in the order.

Normally a profile is pulled in from the Material Master of the production material. If you
have not maintained one, you still have a chance to maintain one here, in the order.

Actions and control included in the Scheduling profile are:


Automatic Release on Creation
Automatic Linking documents on Creation
Automatic Printing of Order on Release
Automatic Scheduling of Order on Release
Automatic Linking of documents on Release
Automatic Creation of Control Recipe on Release
Automatic Goods Receipt from order during Confirmation of last operation
Allowing confirmation or reservation of only an available partial quantity for
components in component list of an order.
Assign a Capacity Leveling Profile, if you are wishing to use Availability check
for Capacity in the order.
If you wish to use capacity Availability checks in order, then you also need to
maintain the Finite Scheduling indicator.
Controls for Automatic Batch creation in an order and batch classifying settings if
required (specifying automatic batch creation at release or save and classifying
in the foreground or background).
Allowing entering a default order type for the plant while creating an order.


Enter the following in the Order Header Screen: Qtys and Date Tab:


This tab gives you an overview of the quantities and Dates




SAP Order Creation - Order Header Dates, Master Data, Long Text & Admin Tab

View the following in the Order Header Screen: Master Data, Long Text and
Adminstrative Tab





The dates/quantities tab will go on filling in the order specific dates and quantities
information. This is self explanatory.

The master data tab contains the BOM and the Routing/Recipe information which is
used to create the order.

There is one more tab at the end which is called the administrative tab which is stores
the information on who created the order and on which date.



Enter the following in the Order Header Screen: Long Text Tab





The order header, long text tab is free for use to insert any order specific information in
it. Long text is an unlimited space to enter process or production related values. Unlike
the short text, the long text has no limitation of characters that can be used. The short
text normally has only 40 characters to use from.



View the following in the Order Header Screen: Administrative Tab:


This tab gives you information on the date the order was created and the user who
created the order






SAP Order Creation - Operation Overview and Detail Screen

Enter the following in the Order Operation Overview Screen & Operation Detail
Screen


Operation Overview Screen:




The order operation overview screen contains the list of operations assigned with work
centers/resources and arranged in a sequence of processing.

You can see the operation list only when the Routing/Recipe is pulled in to the order.
Nevertheless you can change the operation list in the order as required.

Adding or Removing Operations:
You can add + you own operations in the order or you can remove operations -, if
required. When you add an operation, it is not mandatory at all the add a work center or
control key or a description, thus you can escape without entering any field values in the
operation overview or the operation detail screen.

Atleast one operation should exist in the Order Operation list: The selection of
Routing/Recipe in an order can be configured as any one of the option in the table
below. But when you have chosen the option where the selection of Routing/Recipe is
Mandatory, a task list has to be pulled in the order, or else the creation of order aborts.
But when you have chosen the option of Routing/Recipe selection optional and a task
list selection is not mandatory and the order can still be created provided you have
configured a default operation for the order type. Therefore we can say that the
operation overview of an order requires atleast one operation in it for the order to get
created.

0 No routings or reference operation sets to be used
1 Always reference operation set (no routings selected)
2 Routing/ref. op. set mandatory (automatic selection)
3 Routing/ref. op. set optional (automatic selection)
4 Routing/ref. op. set optional (manual selection)
5 Routing/ref. op. set mandatory (manual selection)
6 Routing mandatory (automatic selection)
7 Routing mandatory (manual selection)
8 Routing optional (manual selection)
9 Routing optional (automatic selection)

The relevance of all the field in an operation overview and operation detail screen is
explained in detail in the SAP Routing/Recipe section of this website:
http://www.sapsword.com/home/learn-sap-pp/sap-routing-recipes


Operation Overview fields in a Production Order:


Operation Number
Sub operation
Work center
Control Key
Standard Text
Operation description
Current Operation Status
Operation Start Dates
Operation Finish Dates
Indicator: whether components are assigned to it
Indicator: whether PRTs are assigned to it
Indicator: whether Trigger points are assigned to it


The Operation Overview field in a Process order contains:

Operation number
Phase number
Resource
Control Recipe Destination
Control Key
Standard Text
Operation/Phase Description
Current Operation/Phase Status
Operation/Phase Start Dates
Operation/Phase Finish Dates
Indicator to show for each operation, whether components are assigned to it
Indicator to show for each operation, whether PRTs are assigned to it
Indicator to show for each operation, whether Trigger points are assigned to it



Operation Detail Screen:





The Operation detail screen can be accessed to edit or view, in an order by selecting
the operations/s or phase/s, using the following path:

When you add an operation to the order, you have to enter the field values included in
the operation overview screen. These field values in an operation overview or in the
operation detail screen are not mandatory for entry when you add an operation.

All the fields of the operation detail from the Routing/Recipe are pulled in the order and
are arranged in a tabular fashion.

The relevance of all the field in an operation detail screen is explained in detail in the
SAP Routing/Recipe section of this website: http://www.sapsword.com/home/learn-sap-
pp/sap-routing-recipes


Sub-operation dates

This is a display only tab in the operation detail screen and it shows the start dates and
finish dates for the sub-operations assigned to the operation. This option is not included
in the process manufacturing. In process manufacturing you have phases assigned to
operations and there is no trace of sub-operations in process manufacturing.


Quantities/activities

This is a display tab in the operation detail screen and it shows the quantities that are to
be confirmed and that which are already confirmed. It also shows the scrap quantities,
both planned and confirmed.


Confirmed dates

It shows the operation start and finish dates, both planned and confirmed dates.


Assignment of capacity requirements:

At the operation detail level you make assignments of the individual capacities declared
in the work center, i.e. you can actually decide which machine or labor is to be actually
used to execute the operation and also split up the total operation quantity between the
capacities. Splitting the operation quantities between the individual capacities reduces
the total operation lead time and gives you accurate information on the machine or labor
that was used for execution. This facility is only available for discrete manufacturing or
repetitive manufacturing (if you use production orders there).


Scheduling and Capacity Generation in an order:


Operation Scheduling and Capacity Generation: The operation standard values derived
(machine time, set up time, teardown time, utilities consumption) is a direct
proportionate of the order quantity. When you schedule an order, the scheduling
formula and the capacity generation formula for each operation derives the total lead
time for each operation. When we add the operation lead times we get the total order
lead time. Note that this has been explained in several topics before.


Planned Costing Requirements: At the same when the system calculates the operation
lead times (scheduling and capacity requirement generation) using the standard values
like machine time, set up time and teardown time, it also calculates the planned cost for
each of the standard value (if a costing formula is assigned to the standard values in the
work center/resources).

Planned cost generation example:

For an operation which is assigned to a work center/resource called Finishing, the
following standard value are assigned for a base quantity of 1 Unit

Operation Data Brought in from the Routing/Recipe for Operation 0020 - Finishing
begin_of_the_skype_highlighting 0020 - Finishing FREE end_of_the_skype_highlighting
Operation
0020
Standard
Value
Parameters
Standard
Value for a
base qty
Costing Formula assigned to
the work center/resource in
the costing tab
Activity Rate
assigned to the
cost center for
the work center
Finishing Setup Time 1 HR (Setup time X Operation qty) /
Base qty
$10/HR
Finishing Machine
Time
1 HR (Machine time X Operation
qty) / Base qty
$100/HR
Finishing Water
Required
100 L (Water Required X Operation
qty) / Base qty
$1/L
Finishing Electricity
Required
1 KWH (Electricity X Operation qty) /
Base qty
$20/KWH

Costs derivation at the operation 0020 - Finishing begin_of_the_skype_highlighting 0020
- Finishing FREE end_of_the_skype_highlighting
Standard
Value
Parameters
Value for a
base qty
Order
Qty
Costing Formula Total Activity Cost
for the operation
Setup Time 1 HR 100 Units (1 X 100) / 1 HR = 100 HR 100 HR X $10 = $
1000
Machine
Time
1 HR 100 Units (1 X 100) / 1 HR = 100 HR 100 HR X $100 =
$10000
Water
Required
100 L 100 Units (100 X 100) / 1 L = 10000
L
10000 X $1 =
$10000
Electricity
Required
1 KWH 100 Units (1X 100) / 1 KWH = 100
KWH
$100 X $20 = $2000
Total Planned Cost at the
Operation
$ 23000

Similarly the costs are calculated at all the operations in the routings.


SAP Order Creation - Component Overview Screen

Enter the following in the Order Component Overview Screen



Component Overview Screen:





Component Detail Screen:






The Component overview screen contains the List of components pulled in from the
BOM. The quantities are proportionate to the Order quantity. The Quantity required of
each component is called the requirement quantity.

Every component that is pulled in from the Standard BOM would be represented as a
Line Item in the Component overview screen.

When you are in the creation mode of the order, the standard BOM is pulled in and a
reservation list is created by the system which contains these components. A
reservation list is a direct copy of the component list.


Adding or Removing Components

You can add + you own component in the order component overview screen or you
can remove components -, if required. When you add an components, the system
forces you to enter the following:

Operation number to which it should be assigned to
The Item category of the component
The Component quantity required for production of the order quantity
The Unit of Measure of the component if the same is not maintained in the
Material Master or BOM
The Plant of the component is defaulted to the Production Plant of the order, in
cases where you are issuing a component from alternate plant, it would pick up
the same from the material master's Special procurement key - withdraw from
alternate plant
If the Component added is a Phantom Header Material, the system needs you to
choose addition of component with BOM Explosion or without BOM explosion. If
you add the Phantom Material with BOM explosion then the components of the
Phantom Material BOM are pulled in the order and if you add the Phantom
Material without BOM explosion, only the Phantom Material itself is pulled in the
order

Every Line item in the Component Overview screen contains the following:



Line item number

The line item number normally increases in an increament of 0010. This is configured in
the order dependant parameters.


b) Component

This is the component number brought in from the Standard BOM.


c) Component Description

The component description is the standard component's material master description.
This description cannot be changed in SAP. It can only be changed in the material
master change transaction code.


d) Component quantity required for the order & UOM

Component quantity or the requirement quantity, is the standard BOM quantity multipled
by the Order quantity. Though if there is a scrap quantity maintained at the order level
or the component level, this requriement quantity is increased by the scrap percentage.

You can manually change this quantity in the productin order.


UOM : The component UOM is fetched directly from the standard BOM. This is also
know as the issue UOM. The material when it will be issued to the order, it will be
issued in the UOM mentioned here.


e) Component Storage location as brought in from

This is the component storage location from which the material would be issued to the
order.

- the material master: Issue Storage location field or
- the standard BOM: Issue storage location at component level

you can change the issue storage location manually in the order.


f) Component Item Category

- "L" for Stock Item
- "N" for Non Stock Item
- "C" for Class item used in Variant Configuration

If the item category for the component is "N" then the system creates a Purchase
requisition (PR) in the order for the component procurement. This PR is inturn
converted to Purchase order (PO). The item category is also changeable in the order.

Configuration Dependancy for creation of Purchase Requisition:

This setting is also relevant for creation of reservations. Thus we can say that for
creation of reservation and PR, you can configure as following:

-If the Order dependant parameters settings allow for creation of PR/Reservations at
order creation, the option 3 - "immediately" will be choosen.

-If the setting allow for creation "at release", then the PR/Reservations are created at
order creation stage itself.

-If you set it to "Never", the PR/Reservations are never created.

1 Never
2 From release
3 Immediately


g) Component Plant

The component plant in most of the cases is production order plant unless and untill you
are using withdrawl from other plant for the component. To Use Withdrawl from other
plant you have to mark the special procurement key of the component in the material
master as "Withdrawl from alternate plant".


h) Component BackFlush Indicator

If the Component is marked as Backflush component in the material master or in the
work center where it is assigned to, the backflush indicator would be selected.

Though you can select this indicator manually.

If this indicator is set, the component would be issued automatically in the background
during operation or order confirmation.


i) Operation assigned to

The operation to which the component is assigned to will be defaulted in the production
order, if you have done a component allocation in the Routing or Recipe or in the BOM.

If you have not allocated the component to the operations, the system will default to the
first operation number.


j) Requirement date

The Requirement date equal to the operation start date (to which the comopent is
allocated to) is populated for the component. This date can be changed if the operation
start date is changed or rescheduled.


k) Withdrawn Quantity

The Withdrawn quantity is the amount of quantity of the component issued to the order
till date.


l) Component Usage Probability

The component usage probability is brought in from the standard BOM.

If the component are placed in an Alternate group with prorities and strategies, the
usage probability will be calculated in the order component overview.

You can nevertheless change this percentage allocation manually.


j) Reservation number & Reservation Item number

Every component in the component overview screen becomes part of the reservation
list. Therefore every component will contain the Reservation number and Reservation
Item number.

The Production order reservations cannot be changed. They are only for display.


Configuration Dependancy for creation of Reservations:

If the Order dependant parameters settings allow for creation of Reservations at order
creation, the option 3 - "immediately" will be choosen.

If the setting allow for creation "at release", then the reservations are created at order
creation stage itself.

If you set it to "Never", the reservations are never created.

1 Never
2 From release
3 Immediately



Reservation List and Picking List


The Reservation list created from a production order can only be viewed through the
use of transaction code MB23. You cannot change the order reservation nor create one.

You can use the reservation list to Stage material from Inventory Warehouse to Shop
Floor Issue storage location.


Picking List - For every production order or for every reservation list, a picking list is
created. You can use the picking list to issue material to the production order. Picking
list is included in Tcode MB26.



SAP Order Creation - Releasing the order

Releasing an order:


When the order is under the creation mode or the order is under a change mode, you
can release an order. The Production order header screen or the Operation Screens or
the component screens have a "Green Flag" button on the top to release an order as
shown below:






Releasing an order will trigger the following activities:

Releasing an order would change the "CRTD status of the order to "REL"
Releasing would start allowing order confirmations
Releasing would start allowing goods issues to the order
Releasing would start allowing goods receipts from an order


Before Release, the system would carry out an material availability check,
if configured:


The Material Availability checks would check the stock availability of all the components
and if the materials are not available the system would generate a "missing part list"
showing the shortage quantities.

As per the Order availabillity checking rules and controls configuration, the system
allows or disallows the Release of order, incase of shortages.


Before Release, the system would carry out an Capacity availability check,
if configured:


You can also configure the system to carry out capacity availability checks
before release of the order, through the order avialability checking rule and controls.

But to have the capacity availability checked, you should mark the work centers as
relevant to "Finite Scheduling" and the Production Scheduling profiles and capacity
profiles should be configured for capacity availability checks.

The Capacity Availability checks works only in Orders and through the use of this
functionality you can decide on loading the work centers when they are free and
available for use. The system would prompt the free spaces also.






SAP Order Creation - Saving the order

SAP order creation - Saving the order:


When you are ready to save the Order, you should press the save button at the top of
the screen.

Saving the order would save all your changes.

If you have not given any external numbering to the order, SAP will generate an internal
number as shown below.

The following screens would explain you the same:

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