Cours GPA784 : Systmes flexibles de production

Introduction au systme SAP R3

Prvision de la demande avec SAP R3

"Fitter Snacker Company

Document prpar par Marius Talos

Superviseur : Amar Ramudhin (Ph.D.)

05 Mars 2009
Travail raliser

1. Connexion au systme SAP R3............................................................................ 3

2. Introduction ........................................................................................................... 4

3. Module 1 Introduction to Fitter Snacker master data ......................................... 5

3.1. Fitter Snacker Dataset ...................................................................................................................... 5
3.2. Exercise 1: Explore master data in R/3 ............................................................................................ 7
4. Module 2 - Creating forecast for finished products.............................................. 36
4.1. Exercise 1: Product group .............................................................................................................. 37
4.2. Exercise 2: Create SOP Plan for Product Group........................................................................... 40
4.3. Exercise 3: Transfer plan to demand management. ...................................................................... 50
1. Connexion au systme SAP R3

Slectionner DAKAR ECC pour se connecter au systme SAP R/3

Saisir les informations suivantes :

Client : 405
User : ETS-XX
XX est votre numro qui sera dsign au cours de la sance
2. Introduction

Fitter Snacker Company est une compagnie installe aux Etats-Unis spcialiste dans la
fabrication des barres nergtiques (Snacks bars), elle vend deux types de produit
travers lAmrique :
- Barre NRG-A (nergie avance)
- Barre NRG-B (Protines pour le corps)

La hirarchie de la compagnie se compose dun groupe manufacturier divis en deux

centres de travail : centre de cuisson et centre de mlange (Baking line work center et
Standard mixer work center) et dun sige social qui comprend les dpartements
dadministration, dachat, de marketing, de ventes, de finances et de ressources
humaines.

Fitter Snacker Company fait affaire avec cinq fournisseurs de matires premires :
- Farmington Food Product
- Oshtemo Oats
- Battle Creek Baking
- Climax Cereals
- Grand rapids Grains
Elle possde aussi quatre clients installs dans diffrents coins de lAmrique :
- Health Express
- West Hills Athletics CL
- MEIJER, INC.
- Horighton Health Club

Le diagramme 1 montre la chane logistique de la compagnie tudier.

Diagramme 1. Chane logistique de Fitter Snacker Company

3. Module 1 Introduction to Fitter Snacker master data
In this module we will review the master data of Fitter Snacker. At the end of this exercise the
participants should have a good understanding of the master data structure (vendors, plant,
customer, BOM) and the transactions used to retrieve the data.

Fitter Snacker Supply Chain

The Fitter Snacker database was created by Professor Bret Wagner of Western Michigan
University and is widely used by University Alliance members. The Fitter Snacker Company
produces 2 brands of energy bar. Figure 1 shows the Fitter Snacker Supply Chain:

Vendors Fitter Snacker Company Customers

Farmington Food
Product

Health Express
Head Office
Oshtemo Oats

Plant West Hills Athletic

CL
Raw material flow
Standard Mixer work Storage
Battle creek Baking center location
100

Semi-finished product flow

MEIJER, INC.
Storage
location
200
Climax Cereals
Finished product flow
Baking line work center Storage
Horighton Health
location
300 Club
Grand Rapids
Grains

Figure 1 Fitter Snacker Supply Chain

3.1. Fitter Snacker Dataset

The letter XX should be replaced in the course material by your team number. Most of the screen
shots in this course show dataset 99.

Company
Your Fitter Snacker Company is XXFS.

Location
Each company has the following locations:
One plant XXPT with two work centers:
o Mixer
o Bakeline
Five vendors:
o 1000XX Climax Cereals
o 1001XX Grand Rapids Grains
o 1002XX Oshtemo Oats
o 1003XX Battle Creek Baking Supplies
 o 1004XX Farmington Food Products
4 customers:
o XX + 1 West Hills Athletic Club
o 1XX + 1 Houghton Health Club
o 2XX + 1 Health Express
o 3XX + 1 Meijer, Inc

Materials
The plant XXPT of Fitter Snacker produces these finished products:
XXF100 NRG-A
XXF110 NRG-B
These semi-finished products are used in the process:
XXS200 Dough NRG-A
XXS210 Dough NRG-B
These raw materials are bought from the vendors to prepare the dough:
XXR300 Canola
XXR310 Carob Chips
XXR320 Cinnamon
XXR330 Cloves
XXR340 Dates
XXR350 Hazelnuts
XXR360 Honey
XXR370 Nutmeg
XXR380 Oats
XXR390 Protein Powder
XXR400 Raisins
XXR410 Vit/Min Powder
XXR420 Wheat Germ

Storage location
For each type of material we have a storage location:
100 Raw materials
200 Semi finished product
300 Finished product
Purchasing Info Records (PIR)
PIR that exist under plant and vendors for specific materials:
Vendor: 100099 Materials XXR380 and XXR420
Vendor: 100199 Materials XXR380 and XXR420
Vendor: 100299 Materials XXR380 and XXR420
Vendor: 100399 Materials XXR300, XXR310, XXR320, XXR330,
XXR340, XXR350, XXR360, XXR370, XXR390,
XXR400, XXR410
Vendor: 100499 Materials XXR300, XXR310, XXR320, XXR330,
XXR340, XXR350, XXR360, XXR370, XXR390,
XXR400, XXR410
 3.2. Exercise 1: Explore master data in R/3
Connect to SAP

Click on the SAP logon icon on your desktop.

Select your SAP R/3 system and click on Connexion button.

Enter client number, user name and password as supply by your instructor. And click on
enter .
You are now in R/3 in the SAP Easy Access menu initial window.

To display technical names go on Extras and choose on the list Settings.

Check Display technical names box and then click on Enter.

You can access the transaction using the SAP Menu path or by entering the transaction code in
the command file.
The technical name for the Change Material transaction is MM02.

Example: In the command field type MM02 and then click on Enter to start the transaction
Change materials.

Or through the SAP Menu tree:

Click on then Menu path: Logistics Material management Material Master Material
Change Immediately

We will now review the major components of master data elements in Fitter Snacker.
Customers
Fitter Snacker has 4 customers. To display a customer:

Display Customers:

Menu path: Logistics Logistics Execution Master Data Partner Customer Display
Total or transaction XD03

Click on the button in the customer display screen.

Complete with the following information XX* in the Search term and click Enter .

The customers are displayed. Select West Hills Athletic Club and click Enter
The Customer display initial screen is displayed. Click Enter.

Click on the different tabs to see all the views of West Hills. Click Exit to the SAP Easy
Access menu when you are done.
Plant

In the SAP R/3 system, a plant is where we produce, store and distribute goods. It is the most
relevant location for planning. The plant can be a manufacturing or distribution location.
There is only one plant in the Fitter Snacker Company (XXPT).

Display your Plant

To view your plant you need to go to the customizing view:
In the command field type SPRO and click Enter.

In the new screen click

You are now in the customizing section of R/3

Menu path: Enterprise Structure Definition Logistics General Define, copy, delete, check
plant. Click on .
In the new screen select Define Plant and click on choose , or double click on Define
Plant.

The Change View for Plants is displayed. Select your plant number XXPT and click on
Details.

Check your plant details. Click Address to look at the address details of the plant
Click on when you are done. Click on Cancel until you are back in the SAP Easy Access
Menu.
Work center
Production operations are carried out at a work center. In the R/3 System, a work center
represents: machines or machine groups, production lines, assembly work centers, and employees
or groups of employees.

Display Work Center:

Menu Path: Logistics Production Master Data Work Centers Work Center Display or
transaction CR02

Enter your plant XXPT and click on the search button.

Enter the plant XXPT and then click to start the search.
The list of Work Centers appears. Select the BAKELINE and click Copy.

The value has been copied. Click Enter:

The BAKELINE basic data is displayed. Click the Capacities tab.

Click Capacity header button to display Work Center Capacity.
You can see general capacity information. Click Back to the main SAP menu.

To see the characteristics for Mixers (Standard Mixer Work center) repeat the same procedure.
Bill of Materials
A critical input to the MRP process is the bill of material (BOM), which shows how components
and semi finished products are combined to produce the finished product. A graphical
representation of the BOM for the NRG-A bar is shown below:

NRGA
(Case)

Dough NRGA
(lb)

Oats Wheat Germ Cinnamon Nutmeg

(lb) (lb) (lb) (lb)

Cloves Canola Honey Carob Chips Raisins Vit/Min Powder

(lb) (gal) (gal) (lb) (lb) (lb)

The raw materials (Oats, Wheat Germ,etc.) are combined in a mixer to produce a 500 lb. batch of
dough. The dough is transferred to the baking line, where it is formed into bars, baked and
packaged.

To Display a BOM:

Menu path: Logistics Production Master Data Bills of Material Reporting BOM
Explosion Material BOM Multilevel BOM or transaction CS12

Enter your material number (XXF100), your plant (XXPT) and BOM Application PP01
(Production general) then click on .
The multi-level BOM is displayed. Select XXS200 (the semi finished product) on the first level
and click on Where used list .

To produce 7 CS of XXF100 we need 500 LB of XXS200. Click back .

Select the first BOM item (the semi finished product XXS200) and click on Detail .

The material is displayed. Click MRP 2 tab.

The procurement type is E (In house production). Click back .

Choose a material of level two, XXR380 for example and click on Where used .
XXR380 is used to produce two semi finished product XXS200 (Dough NRG-A) and XXS210
(Dough NRG-B). To produce 500LB of XXS200 we need 300LB of raw material XXR380. Click
back .

Select the same material, XXR380 and click on Detail .

The raw material is displayed. Open the selection list and select MRP2.

Procurement type is F (External procurement).

Click back until you return to the SAP Easy Access menu.
Vendor
There are 5 vendors supplying the raw materials used for the production of the NRG bars. To
display a vendor, do the following:

Display Vendor
Menu path: Logistics Logistics Execution Master Data Partner Vendor Display or
transaction XK03

Enter vendor code 1003XX, company code XXFS and purchasing organization XXPR. Click on
the checkboxes as below. Click on Enter .
The vendor Battle Creek Farming Supplies is displayed. Click on the Next Page button to
look at the Purchasing Data. Click back to the SAP Easy Access menu when you are done.

R/3 Purchasing Info Records

The purchasing info record contains information about a specific material and the vendor
supplying that material like:
Prices and conditions for the purchasing organisation or plant
The number of the last purchase order
Tolerance limits for over-deliveries and under-deliveries
The planned delivery time (lead time required by the vendor to deliver the material)
Vendor evaluation data
The vendor sub-range to which the material belongs
The availability period during which the vendor can supply the material
The info record contains quotation and ordering data.
The data in the info record (such as price) is also used as default data for purchase orders.
You can also maintain the vendors conditions directly in the info record.
Menu path: Logistics Materials Management Purchasing Master Data Info Record
Display or transaction ME13

Enter the following information:

Vendor 1000XX (Climax Cereals)

Material: XXR380 (Oats)
Purchasing Org. XXPR
Plant XXPT
And click on enter
The general data of our Purchasing info record is displayed.
Click on the Purch.org.data
Conditions that include the price and delivery time are displayed.
Click on
Select Valid from 07/13/2004 and click on Choose.

The Gross Price is 0, 20 USD per 1LB. Click until you reach the SAP Easy Access menu.
To have a list of PIR by plant follow the path.

Menu path: Logistics Materials Management Purchasing Master Data Info Record List
Displays By Vendors or transaction ME1L

Delete others entries and enter XXPT plant. Click Execute.

A list of PIRs that was created under plant and vendors will be displayed. Click back until SAP
Menu.
Transportation zone

Menu path: SPRO SAP Reference IMG Sales and Distribution Basic Functions Routes
Route Determination Define Transportation Zone click on

Scroll down until you find US country. We will choose the first zone (MI001). Click Back until
SAP Menu.

End of Module 1
4. Module 2 - Creating forecast for finished products

SAP provides a complete set of forecasting tools that can be used in a number of sales and
operations areas. The most flexible set of forecasting tools are provided in the Sales and
Operations Planning (SOP) transaction. Sales & Operations Planning (SOP) is a flexible
forecasting and planning tool within R/3 with which sales, production, and other supply chain
targets can be set on the basis of historical, existing, and estimated future data. Rough-cut
planning can also be carried out to determine the amounts of the capacities and other resources
required to meet these targets.

SOP plans are transferred to Demand Management (PP-MP-DEM) in the form of independent
requirements. In turn, this data is fed to Master Production Scheduling (PP-MP-MPS) and
Material Requirements Planning (PP-MRP) when planning is done in R/3.

At the end of this module Planned Independent Requirements will be created for NRG-A and
NRG-B Bars over the planning horizon.

Frequently, forecasts and plans are created for a group of products to simplify the process. In this
exercise, we will create forecasts for a product group. The forecast for the product group will
then be disaggregated to the individual products using historical percentages. For this exercises,
we will use a product group consisting of two products: NRG-A and NRG-B bars. We will
assume that, consistent with past sales data, NRG-A bars will make up 70% of sales.
 4.1. Exercise 1: Product group
In R/3:
Menu path: Logistics Production SOP Product Group Create or transaction MC84
Enter the following information:
Product group: XX NRG Group
Description: XX NRG-A and NRG-B product group
Plant: XXPT
Base unit: CS
And then click Enter.

Click on the Member Number field to get the search icon to search for the material number of
XXNRG-A bars.
Enter XX* in the material field and click . Click on the second line and select the XXNRG-B
bars.

Enter XXPT for plant and enter 1 for the Aggregation factor. The Proportion field should be set
to70% for NRG- A and 30% for NRG-B. Click enter .

The aggregation factor specifies how the material consumption quantities of the planning object
are weighted in the planning level's consumption series.
When running forecast, the system determines the consumption series of the planning level from
the individual consumptions of its members.

The system will complete the data of the materials with a description and material type. Click on
Product graphic tab . Save your product group.

When you click on the save icon, you should get the following message:

A graphic view of the product group is displayed. Click on Quit and then on Back until
you reach the main SAP Menu.
 4.2. Exercise 2: Create SOP Plan for Product Group

We will input historical sales data for the two products that make up this group to generate a
forecast.

Menu path: Logistics Production SOP Planning For Product Group Create or
transaction MC81

Enter XX NRG GROUP and plant XXPT, then click on the enter icon.

On the popup, leave the default entry and click on the check mark. Record the version
number.
The Create Rough Cut Plan window will appear. To create a forecast in SOP, follow the pull-
down menu path: Edit Create Sales Plan Forecast

In the pop-up window, enter the values as below and click on the Historical button. Confirm the
message if a pop up appear.
The SAP system will
create a forecast for
13 months starting
with this month.

If available, the system

will use 5 years (60
months) of historical
data

Check Season.trend
models radio button.

The default forecast profile for

SOP (SAP Profile) determines
the default forecast parameters.

Click on Historical to create the

historical data
Accept the message.

Enter in the fields Corr.value the following 12 values. The first value of historical data is for last
month. T refers to current month.

T-1 338
T-2 419
T-3 524
T-4 422
T-5 308
T-6 403
T-7 490
T-8 357
T-9 280
T-10 364
T-11 427
T-12 328

Corr.value

Click on the interactive graphics icon

Click on the interactive graphics icon to display graphs of historical sales data. Two graphs
are displayed:
 Click on the
Historical (corr.)
to display graph

The graph can

be modified
interactively

Click on the Copy

icon to update values
to be used as
historical values

We will return on the screen Forecast Historical Values

Click on the Forecasting button to

display the forecast parameters

Forecasting procedure will test for Trend and Seasonal components.

Click on the forecasting icon again to
generate the forecasts.
The forecast results will be displayed.

Click on interactive graphics to

evaluate the forecast.
This window shows the forecast values in tabular format. The SAP static graph provides a good
comparison of the forecast to the historical data. Click on Legend button to view the legend.
Click on to close the graphics.

Historical Data

Forecast
You will return to the forecast Results screen:

Click on the enter icon to save the forecast and transfer

it to the sales line of the Create Rough Cut Plan screen.

Save your plan .

You will receive a confirmation message. Record the plan number. Click back to the main SAP
menu.
 4.3. Exercise 3: Transfer plan to demand management.

The Sales plan created in SOP has to be transferred to Demand management to create the Planned
Independent Requirements

Menu path: Logistics Production SOP Planning For Product Group Transfer Product
Group to Planning or transaction MC75

Click on the radio button Sales plan for material or PG members as proportion of PG. Enter
the plan number recorded at the previous step (your version).
And click Transfer now.

You will receive the following message. Click on

To see the results click to the SAP Easy Access Menu

Menu path: Logistics Production Production planning Demand Management Planned

Independent Requirement Change or transaction MD62

Choose radio button Product group and enter the following values:
Product Group - XX NRG GROUP
Plant XXPT
And click Enter
The planned requirements are shown in the table below.
On the first period the value for NRG-A is 176 CS and for NRG-B is 75 CS because our Product
group (251CS after forecasting) was created with 70% NRG-A and 30% NRG-B.
Click on the Items tab.

The total quantity for NRG-A is 2560 CS and for NRG-B is 1098 CS over the planning period.
Select the first line and click on the Sched.lines tab
The planned quantity and value per month for the material selected are displayed.
Save your planning and click back to the SAP Easy Access menu.

End of Module 2