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SAP PP
time.
b) Work scheduling makes BOMs the basis for planning operation and shop floor control .
c ) The departments responsible for
i ) handling reservations ,
ii ) Good issues ,
iii ) sales order use BOMs as an aid to enter an Data ,
d ) Product costing uses BOMs To calculate material usage cost for a Product
BOM Categories:
A ) Material BOM
T Code - CS01
B ) Order BOM
T code - CS61
C ) Document Structure
T code - CS11
D ) Equipment BOM
T Code - IB01
T code - IB11
A) Material BOM;
It represents the structure of the Manufactured Product in SCM.
B) Order BOM;
It produces a product for a Specific Sales Order
C) Document Structure;
a) It consists of several documents such as ,
1. A program,
2. Technical Drawings,
3. Paper Documents,
4. Photographs.
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BOM Usage:
It allows you to create separate BOMs for various areas within the company.
Examples of BOM usage:
A)
Engineering BOM
B)
Production BOM
C)
Costing BOM
A) Engineering BOM;
It is the combination of all the components of the products from an Engineering perspective.
It contains all the Technical Data.
B) Production BOM;
It is set from a Manufacturing Perspective.
E.g. process Data is required for assembly Purposes
C) Costing BOM:
It is for automatically calculating the material usage and cost of a Product
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1.
Enter T-code CS01 in the command field. ( SAP Easy access Screen )
2.
Step-3
Click on save button. A Message as
will be displayed.
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BASIC DATA
BOM
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Press F1
In the technical type Screen Area Select the Multilevel BOM inactive checkbox :
In customizing Choose,
Production
BASIC DATA
BOM
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Details screen select the multilevel BOM inactive Checkbox under Technical type
Press F1
The above Screen appears
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WORK CENTER;
A WORK CENTER IS A LOCATION WHERE A PERTICULAR OPERATION IS EXECUTED.
EXAMPLES;
THE FOLLOWING CAN BE DEFINED AS A WORK CENTER
A ) INDIVIDUAL WORK CENTER
B ) STATISTICAL WORK CENTER
C ) PRODUCTION LINE
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VALUE
1000
CENTER 07
0003
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value
Pump assembly
007
009 ( all task list types )
sap1 (Normal production )
set up
should be entered
Matchine -- must be entered
Labour
--- no checking
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1) Scheduling
When a production order is created, the duration of an operation can be calculated based on operating times in routing
and formulas which are entered in the Work Centre.
2) Costing
The costs of an operation can be calculated in the production Order based on the formulas which are entered in the
Work Centre. Work Centre is also linked to a cost centre.
3 ) Capacity Planning
The available capacity and formulas for calculating capacity requirements are stored in the Work Center.
Group of similar machines can also be created as a single Work Centre. For example, 5 similar machines can be created
as 1 Work Centre with a number of capacities as 5.
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Step I )
1) From SAP Easy access open TRANSACTION CODE CR01
Enter your manufacturing Plant code where Work Centre needs to be created.
Enter Work Centre code.
Enter the Work Centre category as "0001" which means Work Centre would be categorized as machines.
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Step 2)
In this Screen, Work Centre basic data would be entered as given below.
Input Work Centre description.
Enter person responsible code for that Work Centre.
Enter physical location where Work Centre is located in the plant.
Enter usage as "009" which means Work Centre is valid for all task list types such as production routing, maintenance task
list, etc.
Enter standard Value key which contains different activity types used for standard cost calculation.
Step 3)
In this Screen under "Capacities Tab."
Enter Capacity category as "001" which represents machine category.
Input processing formula as "SAP006" - It is used to calculate the available capacity of Work Centre.
SAP006 =( Operation quantity* machine time )/ base quantity
After filling in the capacity category and processing formula, click on the
button:
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Step 4)
In this Screen under capacities Tab, capacity data will be entered.
Enter Capacity description.
Enter details about "Input capacity planner group", which is responsible for machine capacity.
Enter factory calendar ID, which has public holidays listed for your plant. So, on holidays, capacity for that Work Center
would be zero.
Input base unit of measure as "MIN" which means work centre available capacity will be measured in time i.e. min.
Enter the time period (start and finish time) for which Work Centre would be available for operation.
Enter capacity utilization percentage %( how much time it is utilized out of the standard available working time) of the Work
Centre considering the breakdown and preventive maintenance of the machine. Input number of capacities which means a
number of similar Work Centre.
Check "relevant for finite scheduling and "long term planning" flags which indicate if there is a capacity constraint, then the
operation is moved to a certain date where it can be processed without capacity constraints.
Then click on the tab "Scheduling" tab from the menu, the system will show the following screen:
Step 5) In Scheduling Tab,
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Enter Capacity category as "001" which represents machine category and hence machine time would be the basis for
calculating schedule time in production order.
Input processing formula as "SAP002" which is used to calculate scheduling time.
SAP002 = (Operation quantity* machine time)/ base quantity/no. of splits.
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Click button
SAP PP
message
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POOLED CAPACITY;
1 ) A pooled capacity can be assigned to several work centers.
2 ) It is created and edited independently of the work center.
3)This is useful if, for instance, a group of employees works in several work centers.
Reference Capacity:
1) A reference capacity is used to simplify the maintenance of work center capacities.
2 ) It is used to copy or reference an available capacity from.
3 ) Reference capacities are created and maintained separately from work centers.
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Routing;
Definition
A routing is a description of which operations (process steps) have to be carried out and in which order to produce
a material (product).
As well as information about the operations and the order in which they are carried out, a routing also contains details about
the work centres at which they are carried out as well as about the required production resources and tools (includes jigs
and fixtures).
Standard values for the execution of individual operations are also saved in routings.
Routings (generic) consist of the following objects:
Routing
Rate routing
Reference operation set
Reference rate routing
Use :
A routing is used as a source for creating a production order or a run schedule header by copying.
Structure
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Routing
Integration:
B)
In the graphic the three routings in group A are identified by their group counter
1,2 or 3.
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Group
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Step 1)
From SAP Easy access menu, open Transaction code CA01
1.
2.
3.
Enter the Key date (valid from date) which means that routing would be valid from that date.
"Header Details"
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Step 2)
In this step, we will maintain routing header data as given below.
1.
Enter Usage as "1" which is meant for Production routing and will be used in Production Order. There are other task list
usages which are meant for Plant maintenance and inspection plan.
2.
Enter Status as "4" which is a released status. It indicates that routing is valid for material requirement planning and
costing.
3.
Enter Lot Size as "99999999" which means that routing is valid for order quantity between 0 and 99999999.
4.
Press Operation button to add the sequence of operation and follow next step 3.
Some information such as Description, Group Counter and Basic Unit Measure will be populated by system automatically.
Step 3)
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2.
Input Control Key which determines whether operation should be scheduled, costed and if auto goods receipt is possible
while doing production confirmation. It is generally configured depends upon your business process.
3.
4.
Input the base quantity or output quantity of the material which indicates how much quantity of material would be
produced in machine and labour time mentioned at point no. 5 & 6.
5.
6.
Click
message
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2.
3.
Key date (valid from date) which means that routing would be valid from that date is set to current date automatically.
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Step 2)
After filling in all the fields, click (right mark sign)
1.
Change the control key from PP01 (without auto GR indicator) to PP03 (Auto GR indicator).Auto Goods Receipt means
when you do production confirmation, Goods receipt of material will happen automatically.
2.
to save Routing.
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2.
3.
Key date (valid from date) which means that routing would be valid from that date is set to current date
automatically.
sign from top menu to go to the next screen and display the routing.
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Step 2) In this screen we will see, how the operation data of routing is displayed.
1.
The screen will display the operation data of routing like operation carried out by the work center, base
quantity (100 EA), set up time (10 minutes) and machine time (35 minutes.)
Troubleshooting
There might be the case wherein material master record does not exist. For this, you need to create the material master
for the material before creating routing.
Some users might get error "work centre does not exist". In this case, work centre should be created beforehand.
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