Right Solution, Right Time, Right Price

PP Master Data Workshop

SAP America Inc. PP Master Data ppt Jan, 1999

Business Process Workshop

The objectives of the PP Master Data workshop is to:
Demonstrate maintenance of master data
Discuss Company master data

Communicate scope expectations

SAP America Inc. PP Master Data ppt Jan, 1999

Agenda
Attendees:
Production, Costing

Topics:
Material Master
BOM
Workcentre

Routing

SAP America Inc. PP Master Data ppt Jan, 1999

Master Data
Master
Master data
data

Material Master
Record
BOM

Routing

Item
10
20
30

Operation
10
20
30

Work centre

Master data is comprised of material master records, bills of material,

routings and work centres.

The material master is the foundation for all logistics functions of the
SAP R/3 System.

SAP America Inc. PP Master Data ppt Jan, 1999

Views of the Material Master

Basic Data

MRP
Stocks in plant/
storage location

Storage

The
The material
material master
master is
is aa
central
central data object for all
material
material types:
raw
raw materials
materials
semi-finished products
products
finished products

Costing

Sales
Work
scheduling
Quality
management
Forecasting

Classification

Each
Each user
user function
function has
has its
its own
own view
view of
of the
the material
material master
master
which
which permits
permits easy
easy access
access and
and maintenance
maintenance of
of data.
data.

SAP America Inc. PP Master Data ppt Jan, 1999

Not included with PCC

Accounting

Purchasing

Basic Data View

Required fields on the Basic Data View screen include:
Material Description: specified at the client level within
the R/3 hierarchy
Base Unit of Measure

Specified at the client level within the R/3 hierarchy

Examples include:

Each
Pound
Centimeter
Kilogram

SAP America Inc. PP Master Data ppt Jan, 1999

Days
Litre
Minute
Etc. (You may also
specify your own)

Important Fields MRP1 View

MRP Type: A key that determines whether the material will be planned,
and if so, how it will be planned. Planning options include MPS, MRP or
reorder point.
Planning Time Fence: The number of days in which automatic changes
cannot be made to the master plan.
MRP Controller: A unique number that identifies the MRP controller or
group of MRP controllers responsible for planning material requirements.
Lot Size Key: A key that specifies the strategy, (e.g., Lot-for-Lot, Fixed
order quantity, Part period balancing, etc.) the system uses during MRP
to calculate the quantity to be produced or procured.

SAP America Inc. PP Master Data ppt Jan, 1999

Important Fields MRP1 Contd.

Procurement Type: An alphanumeric key that signifies how the material is procured either in-house (E), externally (F), or
both in-house and externally (X).
In-house Production: Number of days required to produce the material in-house, independent of lot size.
Scheduling Margin Key: A numeric key that determines the floats and opening period required for scheduling an order.
Reorder point planned materials: If the on-hand stock falls below the reorder point quantity, MRP will create a replenishment
based on lot size rules and values defined in the material master record.

SAP America Inc. PP Master Data ppt Jan, 1999

Important Fields MRP2 View

Strategy Group: A numeric key that contains all the possible planning
strategies (e.g., make-to-stock).
Availability Check: A key that specifies if and how the system checks
availability and generates requirements for MRP.
Consumption Mode: A numeric key that indicates whether forward or
backward consumption is performed.
Consumption Periods (Backward/Forward): These fields specify the
length of time (in days) of the consumption period for backward and forward
consumption respectively.

SAP America Inc. PP Master Data ppt Jan, 1999

Important Fields MRP2 View

Individual/Collective: A numeric key that indicates whether individual
customer requirements planning (1), collective requirements planning
(2), or both (blank) are allowed for the dependent requirements of the
material.
Discontinuation Indicator: An indicator that identifies the material as a
material/part to be discontinued and controls the discontinuation
process in materials planning.

SAP America Inc. PP Master Data ppt Jan, 1999

Work Scheduling View

Shop Floor

Engineering

Production

Which departments use this view?

??

Engineering

Shop Floor Production

Materials

Materials Management

Management

Why is this view used?

SAP America Inc. PP Master Data ppt Jan, 1999

To record data related to production such as:

Units of measure
In-house production time
Delivery tolerances

Costing and Accounting Views

Finance

Purchasing

Which departments use this view?

??

Finance

Purchasing

Cost
Accounting

Cost Accounting

Why is this view used?

SAP America Inc. PP Master Data ppt Jan, 1999

To maintain standard cost

To maintain average cost

Discussion
What Materials/attributes must be set up ?

FG, Semi, Raw, externally procured, free from Customer

What attributes for Materials must be set up ?

UOM, Safety Stock, Floats

What is the volume of data to transfer ?

What is the volume of new materials/wk - 400 ?

SAP America Inc. PP Master Data ppt Jan, 1999

Bill of Material Definition

BOM

AAbill
billofofmaterial
materialisisaacomplete,
complete,formally
formallystructured
structuredlist
list
ofofthe
components
of
a
product
or
assembly.
A
bill
of
the components of a product or assembly. A bill of
material
materialcontains
containsthe
thedescription
descriptionand
andobject
objectnumber
numberofof
each
eachcomponent,
component,the
thequantity
quantityand
andunit
unitofofmeasure.
measure.

SAP America Inc. PP Master Data ppt Jan, 1999

Multi-level BOM
Motorcycle

Power Train

Motor

Gear

Exhaust

Chassis

Front
Wheel

Rear
Wheel

Frame

Combining
Combiningsingle-level
single-levelBOMs
BOMscreates
creates
aacomplete
multi-level
structure.
complete multi-level structure.

SAP America Inc. PP Master Data ppt Jan, 1999

Brake
System

BOM Categories
Material
Material
master
master
record
record

A bill of material can only be created for

an object that has a material master
record in the system.

The BOM category determines whether

the BOM is created for a material,
equipment, or document.

Material BOMs are used to represent the

structure of the products manufactured.

Material
MaterialBOM
BOM

Equipment
Equipment
master
master
record
record

Equipment
EquipmentBOM
BOM

Document
Document
info.
info. record
record

Document
DocumentBOM
BOM

Not included with PCC

SAP America Inc. PP Master Data ppt Jan, 1999

BOM Validity Period/Area

The area of validity and the validity period

define the precise conditions under which a
bill of material applies in different areas of a
company.

The validity area defines which plants may

use or produce an item described by a bill
of material.

The validity period is the time period during

which the bill of material is valid. This time
period is defined by the "valid-from" date
and the "valid-to" date.

SAP AG
1993

Valid-from
Valid-from date
date

SAP AG
1993

Valid-to
Valid-to date
date

SAP America Inc. PP Master Data ppt Jan, 1999

BOM Usage
Engineering
Data

Each area in a company can maintain

its own item data and obtain information
that is directly relevant.

The BOM usage indicates whether the

BOM contains:

Production
Data

BOM
BOM
Costing
Data
Plant
Maintenance
Data

Sales Data

SAP America Inc. PP Master Data ppt Jan, 1999

engineering data
production data
costing data
sales data
plant maintenance data

Planning Scrap
To plan material requirements more precisely, you can allow for a certain
percentage of scrap material. There are three types of scrap:

Component scrap: Only affects a single

component in an assembly. If you explode
a bill of material, the system increases
only the component quantity by the
calculated scrap quantity.

Material
Master

Assembly scrap

Bill of
Material

Component scrap
Operation scrap

Assembly scrap: If you estimate, for example, that there will be 10% assembly
scrap, you will need 10% more of the components that make up that assembly.

Operation scrap: If operation scrap is used in the BOM, it replaces the assembly
scrap from the material master.

SAP America Inc. PP Master Data ppt Jan, 1999

Discussion
What BOMs must be set up ?

What attributes for BOMs must be set up ?

What is the volume of data to capture ?

What is the volume of new BOMs/wk - 400 ?

SAP America Inc. PP Master Data ppt Jan, 1999

Work Centre
A work centre is an organizational unit where
a work step (operation) is performed.

Definition
Definition

Work centres are used in routings. They can also be used

as capacity collectors for statistical evaluations.

Usage
Usage

Examples
Examples

Type of work centre

Example

Individual work centre

Work centre group

Assembly line

Individual person

John Doe

Group of people

Group 12

SAP America Inc. PP Master Data ppt Jan, 1999

Automatic lathe 17
Lathing shop
Line 9

Work Centre Data

General data

Standard values
for routing

Basic data

Default values

Name and description

Standard value key
Performance efficiency key
Control key
Standard text key

Capacity data

Capacity

Scheduling data

Scheduling

Costing data
and
HR data

Scheduling basis
Queue and move times
Formula key

Assignment

Cost centre
Activity types
Formula keys

Available capacity
Formula key

Work
Work centres
centres contain
contain data
data stored
stored in
in several
several screens.
screens.
This
This figure
figure shows
shows some
some of
of the
the important
important data
data stored
stored in
in work
work centres.
centres.

SAP America Inc. PP Master Data ppt Jan, 1999

Functions of a Work Centre

Work
Work Centres
Centres Contain:
Contain:
Default
Values for
Task Lists

Costing
Data

Scheduling data is used for lead time

scheduling.

Scheduling
Scheduling
and
and
Capacity
Capacity
Data
Data

Lead time scheduling calculates order

dates and capacity requirements for
orders.
Capacity data is used for capacity
planning.

Formulas are used for

scheduling, capacity planning
and product costing calculations.

Production Plan
C
a
p
a
ci
ty

Available Capacity
Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec

Time

SAP America Inc. PP Master Data ppt Jan, 1999

Discussion
What Workcentres must be set up ?

What attributes for Workcentres must be set up ?

What is the volume of data to capture ?

Automatic processing required for component Issue and good

Receipts ?

Define the costing, scheduling and capacity formulas?

SAP America Inc. PP Master Data ppt Jan, 1999

Routings
A routing describes the processing steps that must be performed to
produce a material.
Material

Routing group

Operation 20

Operation 10
Work centre
Texts
Control data
Times

SAP America Inc. PP Master Data ppt Jan, 1999

Material components
Production Resources
and Tools

Routings
Routings contain:

The steps required to produce or make an assembly

The work centres where the steps are to be performed

The resources and tools necessary to complete a step at a work centre

Material allocation

The material being manufactured is allocated to the group counter (header)

Component materials are allocated to operations

Standard values for setup, processing and tear-down time

Instructions of what to do at each work step

SAP America Inc. PP Master Data ppt Jan, 1999

Routings
A material can be manufactured in different ways.
For each material, you can create several
routings for different :

Lot size ranges

Work centres

Usages, including

Production
Rework
Prototype

SAP America Inc. PP Master Data ppt Jan, 1999

Routings
Routings are stored in groups of similar or related routings.
Each individual routing is referred to as a group counter within the
group

Routing Group

Group
Counter 01

Group
Counter 02

SAP America Inc. PP Master Data ppt Jan, 1999

Group
Counter 03

Group
Counter 04

Routings
Each group counter has a standard sequence of operations
Each group counter may have alternate sequences and/or
parallel sequences

Group
Counter 01

Parallel Sequence

Standard Sequence

Alternate Sequence

Operation

Operation

Operation

Operation

Operation

Operation

Operation

Operation

Operation

Operation

Operation

Operation

SAP America Inc. PP Master Data ppt Jan, 1999

Discussion
What Routings must be set up ?

What is the volume of data to capture ?

What is the volume of new routings/wk ?

What % routings are for special pkg, repkg, degauss ?

Do you want to have change control on Master Data (material,

BOM, Routing) ?

SAP America Inc. PP Master Data ppt Jan, 1999

Right Solution, Right Time, Right Price

SAP America Inc. PP Master Data ppt Jan, 1999