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SOP-Flexible Planning

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we have seen the Standard SOP in the previous blog,in continuous to that we will review the flexible planning.
Why Flexible Planning?

* SOP has limited features, it has fixed characteristics,Keyfigures and only 3 Planning type.
* In Flexible Planning we can create the characteristics as per our requirement, we can have Sales org,Dist channel, Division etc.
* Keyfigures can also be planned as per requirements.
* Standard SOP does only level By level Planning, But Flexible planning can be done as consistent or level by level also.

we will review the same as step by step.
1. We need to create the self defined infostructures.
1.1. Maintain Self-Defined Applications
* Here we define the applications like Sales,production etc.

1.2.Maintain as Dictionary Structure
* In case if we are not having the required characteristics or keyfigures same has to be created.
* All the required data elements can be created and also maintained in one single structure.

1.3 Self Defined field Catlogs.
* this helps to group the characteristics and keyfigures as required,

1.4 Maintain Self-Defined Information Structures ( MC21)
* Once all the above prerequisites aer done, we can create the Infostructure.
* Generally in the Flexible planning we need to create our own self defined infostrucuture.
* the required characteristics, keyfigures all to be assigned properly.
* The sequence of the Characteristics should be properly arranged.
* Also the planing possible to be selected.

1.5 Info structure planning parameters .(MC7F)
* Once the Infostrucuture is created, the next step is to maintain the planning parameters.
* mostly it will be created as consistent planning.

2.Planning type.

2.1. Create Planning type.(MC8C)
* Planning type is to be created as next step.
* each planning type will be created with reference to the Infostructure only.
* In the planning type Aggregate planing,detailed selection needs to be activated.
* Planning horizon / Standard calculations are to be maintained as per the requirement.
* Also required keyfigures needs to be selected and this will form the planning type.
* Once the planning type is created save it.
* here as discussed in the other blog we can create the required macro and also attach it accordingly.

3.Master Data

3.1. Planning Hierarchy:(MC61)
* First thing to be created is the Planning hierarchy.
* Planning hierarchy is the characteristics values arranged in hierarchy fashions.
* Planning hierarchy is created for each info structure.

4. Planning :

4.1. Create Planning;(MC93)
* First we need to create planning for the required Planning type that we have crated.
* This data to be created at version level.
* In the planning type we can also have few customer functions.
* This customer functions can be activated and can be made to perform as per our requirement.
* once all the planning is done then we can save this.

5. Demand Transfer:(MC90)
* MC90- we can use this transaction to do the transfer of value from one key figure to the demand management.

6. Demand Transfer – mass processing
# All the required steps for the mass processing has been discussed in the previous blog.

I have explained the Flexible planning in high level, it will be helpful for beginners.
let me know if you have any clarifications and feedback

Sales and Operations Planning – Standard SOP

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Sales&Operations Planning – Standard SOP :

SOP is generally used to arrive the demand management with the support of the data from the sales.This blog describes a simple cycle of executing the SOP step by step.

In standard SOP we will be able to do planning at the Product group level or at the material level only.
If we need to different characteristics then we need to look use the Flexible planning. The details of the Flexible planning we will be looking in the next blog.

1. Create Material master.

* Create the materials to which we need plan using the SOP.
* In this we have to ensure that the planning strategy is properly maintained.

2. Create Product Group( MC84)

* Once the maeterials are created we need to create the product group.
* Product groups aer to be created for a plant , the members canbe materials or the product group iteself.
*In the prod group we need to maintain the aggregation factor and the proportionto be maintained correctly.

3. Create Planning (MC81)

* Once the Product group is created we can create the SOP plan in couple of differen Planning type.
* But before we get started with it, it is better to look at the Infostructure, Infstruct Planning parameters& Planning types etd.

3.1. Info structure(MC21)

* In SAP Infostrucutres are tables which can hold the data and also get updated periodically.
* For the SOP we will be using the S076 info structure, this is std sap infostruct we cannot change this.
* this info strucutre is made of characterstics and keyfigures.
* Characteristics will have some characteristics values agains which we will be storing some values for the keyfigures for some periodicity.
* Example for characteristics is Plant,Sales org,material etc.
* Example for Keyfigures are SAles qty,Production qty,Stock etc.
* whenever we create infostructure it will generate 2 table for example for s076 infostructure we can see 2 tabls S076 ans S076E.

3.2. Info structure planning parameters(MC7F)

* Once the info structure is created we will set the planning parametrs for thesame.
* In this we will be defining what type of planning that infostructure will be supporting ,Consistent or level by level planning.
* It also has many other controlling parametrs like Planning, Planniung units, Planning periodicty,System parameters etc.
* Also here we will be having the keyfigures.

3.3. Planning type ( MC8C)

* Planning type, it is layout which has our keyfigures arranged in rows and also the macros are defined here only.
* For SOP we have 3 planning types based on the planning.

for Product group -SOPKA
FOR material – SOPKAM

* Here we can also create few macros.
* Macros are one which can do some predefined function.

4. Planning for a Product Group
* Till now we have seen the set up for the SOP.
* Now we will be doing the planning.
* For the planning use t.code mc81 and enter the product group, plant .
* once the plant is entered it will giving you the version.
* we need to mention the version number all this versions will be inactive version and only AOO version will be active.
* Here once you give the version it will take you to the next screen to enter the values for the keyfigures.
* the standard keyfigures are sales, production,Tgt stock level, and Tgt days supply only here you will be enter the values.
* Now we can enter the sales figures against the sales row,columns will be mentioend as periodicity, this will be as per the periodicity that has been setup in the planning parameters for the info structures.
* now you cansynchronus the sales value to production values or else you can enter your own prodn keyfigures.
* To do synchronisation – go to edit>Create prodnplan
* Once you have entered the Plan now you can save the plan.

5. Version Management.

* when we start the planning we will be doing the planning in an inactive version XXX.
* You can create as many number of Inactive versions.
* this inactive version helps to do iterations
* Once we do finalise the inactive version from which we need to transfer the values we have to convert them into the active version as explained below

5.1 Create Planning with a xxx versions (MC78 – Copy)
* Here you need to define the source version
* then the target version
* when you do the copy version you will get a warning message you can ignore them.

6. Transfer of Demand from SOP to Demand Management.
* Once we have the values in the active version.
* Now we can transfer one key figure values to the demand management in the PIR.

6.1 MC75 – Transfer Product Group to Planning
* In this method we will be able to transfer only one product group values.
* If we need to do in mass the same is explained in the last stage of this topic.
* Now in MC75 we need to define the plant, prod group first.
* Then the Transfer strategy,PIR specs, version of PIR etc.

6.2. Error log
* now during the transfer you can do an error analysis if we had any errors.

6.3 . Display of Demand in PIR
* Once the Transfer is done you can test the same in the PIR. Md63

7. Mass processing of Demand.
* when we need to transfer value from more number of Prod group value we will be using the mass processing.
7.1 Transfer profile -MC8S
* First Create the transfer profile.
* here we have to define the strategy,table,Field name,Version etc.

7.2 MC8T-Activities
* Here we h ave to define Planing type,activity etc.
* Also here we can attach the transfer profile.

7.3 Create Job MC8D
* Create a Job for the relevant planning type.

7.4 MC8G – Schedule
* Using this you can schedule the Job

7.5 MC8J – Post process
* this can be used to do the status check of the job.

with all the above you will be able to do a simple SOP.
Kindly leave your comments for clarifications and feedback.


Calculating the Usage for the PRT.

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Production resources tools :

In most of the manufacturing scenario, there will be few PRT’s like Jigs,Fixtures, Beams etc,. It will be a requirement to track the usage of the same.
One of the way is explained below.

the below scenario will be possible only if you are working in the Discrete Manufacturing environment.

This particular topic has more integration with the Plant maintenance module.

Process Flow:
1. Create a equipment

  • Create an equipment with IE01.
  • When you create the equipment kindly take care in the Equipment category it needs to be P – PRT.
  • Also in the PRT tab now give the required input like usage,Task list type etc.
  • Here in the below there will be a measuring counter , we have to attach this in the later stage.

2. Create Characteristics

  • Use CT04 to create characteristics.
  • Create a numeric Characteristics with description called “USAGE’
  • Also give the Unit of measure as Each / Pieces.

3. Create a Measuring point

  • Use transaction IK01.
  • Here create the measuring point with the equipment which you created earlier.
  • Attach the characteristics usage in the characteristics filed.
  • Also do check the measuring point is also a counter.

4. Attaching Measuring point to equipment/PRT

  • After the measuring point is created, now in the PRT tab as mentioned earlier attach the same in the field.
  • this assignment is very important.

5. Attaching the PRT in the routing.(CA02)

( When you are doing this scenario for the first time, do as described below only)

  • In the routing, go to the operation overview, now attach the PRT as equipment.
  • It will ask you to enter the usage value etc.
  • Here assign 1 and uom as EA/PC whatever you have mentioned in the step2
  • Once you have completed the assignment save this routing.

6. Creation of production order(CO01)

  • Now create a production order for the header material
  • In the operation overview, you can now check if the PRT is assigned.
  • Here you kindly check if the PRT has been attached and also check if the measuring point is also available there.
  • Create,Release and save the production order

7. Production Confirmation ( Co11n)

  • Now do the production confirmation for the production order /Operation for which the PRT has been added.

8. Usage Value( IK03)

  • Now in the IK03 you can display the measuring documents that have created.
  • for each production confirmation you will have individual document getting created.

Now you will have the usage value for the PRT. Since the PRT has been created as equipment we can trigger a maintenance plan etc. from here you can do forward integration to PM module.

9. PRT in orders.

  • For example if we have one PRT called PRT0001 this can be used in only one order at a time.
  • So to track if we have used in many order or in which all orders this PRT has been used.
  • You can use PRT in order T.code.

10. General

  • Generally in the discrete manufacturing environment we can attach during the Production order creation.

Kindly try this and if you have any querry/corrections do post a comment.

Long Term Planning – LTP

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Long Term Planning:

SAP Production planning has the feature of doing a simualation with the Long term planning.
This is a very useful tool which can be used in handy.

Features of LTP:

  • Same master data of the Operational MRP is used.
  • Comparison of the Operatioanl MPR vs Simulative MRP.
  • Planning for All MRP levels.
  • Long Term Planning allows you to simulate demand (sales forecast) to see a) what new kinds of capacity requirements are created, b) new planned material requirements for lower level assemblies and components.
  • If you are happy with the results of the simulated planned orders, you can make them operational.
  • In long-term planning, various versions of the master plan are created which are each tested, in simulative mode, in the planning run and in capacity planning.
  • The system thus calculates the capacity requirements, the activity category requirements of the cost centers, and the purchased parts requirements.

Pre Requisities:

The below are the Pre requisities which i am aware of have been listed below

  1. If the lead time of the material is more and if they wanted to do a forecast.
  2. Mostly in the Make to stock environment.
  3. Planned independent requirement should be maintained so planning strategy which will support the same is required.

LTP – Process flow :

1. Create & Release planning Scenario
2. Defining Long Term Planning Independent Requirements (Inactive)
3. Run the simulative MRP
4. Simulative reporting analysis.
5. Review the results and take action.
6. Copy the results to operative planning ( this is only optional and not mandatory)

LTP – Process Flow Step by Step
1. Create & Release planning Scenario

1.1 – Use T.Code – MS31 ( Logistics-> Production -> Master Planning -> Long-term planning -> scenario -> create)

1.2-Enter the PlanningScenario number,Description, and select the purpose – select LTP.

1.3-Now it will take to the LTP scenario details Here maintain the below ones

1.3.1 – PIR Date reange

a. Here we need to mention the PIR details.
**From Date range
Specifies the beginning of the planning period
**To Date range

Specifies the end of the planning period,

The period is used to define the period for which PIR taken into account in LTP
1.3.2 Control parameters

**Opening stock -Determines how opening stock will be calculated
**Dep reqmts for reorder point materials-This selection determines whether dependent requirements are also to be created for materials planned using one of the consumption-based planning procedures and whether they are include in the planning run.
**Include firmed receipts -This selection takes purchase orders, production orders and reservations into account in long-term planning
1.3.3 -Available capacity
maintain the proper one, this will avoid the scheduling.

1.3.4-Logistics Controlling

the below ones are done to transfer teh data for analsysis, you can leave it blank also.
Purchase info system version
Inventory controlling version
Last transfer to PURCHIS
Last INV. CO data transfer
1.3.5. Plant Assignment :
If you notice closely all the above steps till now we havent mentioned for which plant we are using this LTP.
Now to over come that we need to select the assign plant in the menu and add the plant and also tell the system which PIR version we will be using.

1.3.6. Now once all of the above is done, we need to save and release.
1.3.7. When we release the system we need to activate the Plannign file entry.
( we have covered the 2. Defining Long Term Planning Independent Requirements (Inactive) in the stpes 1.3.5 to 1.3.7)
1.4 Now we have completed created a planning scenario.

3. Run the simulative MRP

3.1 – Enter T.Code MS01 (Logistics->Production->Master Planning->Long-Term Planning->Long-term Planning->Planning Run->Online)
3.2 -you have to give the relevant plant, Control paremeter etc.
3.3- one important thing that needs to be taken care here is whether results need to be copied to the normal mrp.
3.4. If all settings are takencare you can run the tcode.
3.5 – This will run the Simulative MRP for the whole plant.

4. Simulative reporting analysis.

4.1 -T.code MS04 (Logistics->Production->Master Planning->Long-Term Planning-> Evaluations-)
4.2. this is a replicate of the MD04 tcode, here you have to give the LTP scenario number and then the material and plant.
4.3. now you can see the same screen like md04 and most of the features of the MD04 will be available here.
4.4 T.Code -CM38 – You can use the T.code to do the capacity analysis.

5. Review the results and take action.
5.1. once the results are reviewed you can transfer this as an operative planning.
5.2. If you need to do iteration , like to see an What If analysis, then correct the PIR and again rerun the mrp.
5.3. You can do the iteration any number of times, this will not affect our operational MRP.
5.4. you can also compare the simulative MRP with the Operations MRP also.

Configuration Settings:
1. Only the Scheduling parameters in the OPU5 needs to be taken care, apart no other setting we have.

Conclusion:
Eventhough i have covered the same in very high-level this will be a begining point to start few of them, For any assistance do leave on comments.

Rework in Production Planning

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Rework – In most of the manufacturing environment there would be some or other form of rework.
This topic explains how to handle the rework by creating a new production order.

Scenario:
1.When a rework is to be done a new production order is to be created.
2.This production order will not have any material.
3.This will have only one operation.

Assumption
1. A header material HM1 is already setup in the system with all required master data like BOM,Routing,etc.

before we go in detail the below T-codes are the one the person is to be familiar with
Transaction codes:
1. BS02- status profile management
2. CA21- Rate routing
3. C032- Reference rate routing
4. Ca02- Routing change
Configuration:
1.New order type
2.Order type dependent parameters
3.Default operation for the order type / Plant combination.

I.Creation of status profile:

a.Create one status profile Zrework with 2 status in the profile
ex: Initial,Creat.
b.The Status profile should be assigned to object types.

II.Create a separate order type
a.Create a separate order type
b.Set up the order type dependent parameters
c.Now assign the status profile in the header and in the operation in the created order type

III.Create Rate routing
a.Create a simple rate routing

IV.Create a Trigger Point.
1.Create a trigger point with co31.
2.In the Trigger point assign the status(create ) for the function – create a new order
3.Double click the assigned status this will pop an additional window to fill in the group,group counter and order type.
4.Fill in with the rate routing no and also the created order type

V.Routing – Trigger point.
a.Now the trigger point has to be assigned to the routing of the header material HM1.
b.To assign this double click on the operation and in the Menu – find the trigger point and assign the trigger point a pop up window requests you if to copy from std trigger point – confirm yes.
c.After the trigger point is assigned save it .

VI.Test Rework Scenario.
Step1.Create a production order for the header material HM1-release and save it.
* Check in the status management if the status ZREWORK.
Step2.Now confirm the production order with Co11.
* When you confirm make the yield as zero and also delete if any goods movement was there
Step3.Now save the confirmation,When you save the confirmation you will get a trigger point message – confirm the message it will take you to the next screen where the triggerpoint with the function to create the production order would be displayed.
step4.Now execute the trigger point.This would generate a production order.

Now the production order without material is created,

The above explains the rework scenario in higher level , with this input try out the rework cycle as per the business requirements.
For further details about the process are if you are struck anywhere post with a comment

Classification View in PP-Part 1

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I have used the classification view in different areas.I just wanted to share the information.
classification view can be attached to the below master data.
1.Material master.
2.Work center
3.Routing.

1.Material master:
we can use the material class to store the information regarding to the material which is at the client level.this will help for us to maintain the characteristics of the material.

2.Work Centre:
we can use the classification view in the work centre.
Like if we are having different characteristics like machine speed,machine load, weight of the machine,make ,year of manufacturing thing like this can be created as characteristic

3.Routing:
we can use a routing class to be attached to each routing and this information can be used to reproduce in reporting or to print in the shopfloor paper.

There are still more usage of this classification view like in batch management also.
kindly leave your comments if you need more information.

Production Planning Process Flow

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I like to explain the Production Process flow for a simple demand to stock cycle.
Step1.
1.1.Create a demand in the md61 transaction for a plan and material combination.
This has to be maintained for the Finished goods material only ie) which has a BOM and a routing.
1.2.Here ensure that the version check box is selected ,becoz only if it is selected it will be considered for MRP Run.

Step2:Run MRP
2.1.Now using the transactin Md02 give the same material and plant and run the MRP.
2.2 In the MD02 screen the Planning Paremeters are to be selected accordingly.
2.3 Execute the transaction.

Step3:MD04 stock requirement List
3.1.Now you can use the Md04 transaction to view the Demand created by Us and also the proposal generated by the system if there is shortage of supply for the demand.
3.2. System generats Planned order.
3.3. Double click on the planned order no , which will help us to convert the planned order into an production order.
3.4 Now you can create the Production order.
3.4 In the same step you can release and save the order.
3.5 Now in the Md04 screen on refresh we can view the Production order number on display.

step4: Production order
4.1. Using Co02 we can view the status and also the BOM,Routing etc that has been copied from the master data to the production order.

Step5: Production order confirmation.

5.1. Using CO11N confirm the Production order operations.
5.2. To avoid any error in the stock posting we should confirm the production for the previous operations or order which will be increase the stock of the finished goods.Also the required purchase material stock is also to be checked.
5.3. During the production confirmation of the final operation we can view the goods movements of the material produced and also the material consumed.
5.4. execute and save the transaction.

Step6: GR/GI check
6.1 now we can check the goodrecevied and also goods issued with different transactions
6.2 Co03 – in this you can use the Documented goods movement to view .
6.3 MB51-Material document list.
6.4.Coois – Order information list.

SAP-PP Master Data

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Production Planning Master data:
The below are the few master data that will be required based on the business scenarios.
1.Material master – with MRPView,Workscheduluing
2.Bill of material
3.workCentre
4.Routing.
5.Production version.

Details about the master data:
1.Material Master:

1.1.MRPviews: The MRP view is the one which will have the MRP parameters like MRP type,MRG group,lotsize,strategy,Avaialability check etc.
1.2.WorkScheduling:This view has to be activated if we are working with Production order scenario.This also helps you to maintain the serial numbering and attaching a production scheduling profile.

2.BIll of material:
BOM master data is used to hold the details of components that are required to produce a finished goods.Also in the bom we can define the required scrap % for a component.And we can also control the below few parameters like Bulkmaterial indicator,relevant for costing,phantom material indicator etc.
BOM item category is important. ex:stock item,text item,class item etc.

3.Workcenter:
Generally the machine and the labour in the shopfloor are mapped to the workcentre in SAP.
Workcentre category is important one to choose.
each work centre has views like general,default,capacity,scheduling,costing etec.

General:we maintain the basic parameters.

Default:Here you have the default values for a workcenter.

capacity:Here we define the default capacity that are required to use and also the forumlae requried to calculale the capacity is also defined here.Also the capacity parameters related to the workcentre will also be maintained here.

scheduling:The scheduling of the workcentre can be done based on any one of the parameters like machine,labour etc.The formulae used for scheduling is to be maintained here.

costing: Here we map the cost centre to which the workcentre costs are to be accumulated.
the activity and activity type will be linked here with the formulae.

4.Routing:
This master data tells on the route on which the rawmaterial travels and gets transformed into different semifinished goods and finally into the finished goods.
here you can define the operations and also the workcentre or machine on which the operations are carried out.
Also the parameters for each operation with the standards, time required,labour required etc all can be defined here.
Also if the particular operation requires some inspection then the same can be defined here.
Routing is important master data which integrates with the quality module.

5.Production version:
when a product can be produced with multiple bom and routing combination then we define the production version.Each production version will be assigned a BOm ,routing and also validity period,lot size.

SAP Production Planning

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I like to skip the introduction to basics of SAP and directly jump into the Production planning of SAP.
Production Planning&Control module which is allways called as PP module takes care of the planning process of material ,after planning it helps to produce the material through production and then apply the controlling process over the Planning and also the production.

SAP-PP module can help the production through discrete and repetitive manufacturing process.

what is discrete manufacturing?
discrete manufacturing will have shorter order quantities, the process will not have continious flow and mostly if the business requires to monitor the cost at an production order level then the system is configured for dicrete manufacturing
What is Repetitive manufacturing?
In this process thegoods will be produced in larger quantities and the business likes to collect the cost at the material level and that too for a certain larger periods.

I like to discuss this in the begining itself as the later production process will be based on the manufacturing type