Check Points/Control Parameters for the PP Module

[Former Member]

Hi Experts,

Since we are dealing with Business scenarios for the manyfacturing industries,

as industry set for the process parameters,control parameters,work instructions,standard operating systems,identification of the critical parameters which then help in failure mode and effect analysis and process failure mode and efefct analysis.

Such process help for both DESIGN and PRODUCTION to curb the quality of the products,'

Since we are long go on SAP PP Module,I would liked to request PP Experts to share their views on check points / control parameters to

ensure the smooth running of the SAP Production planning module,which contents the following area,

Check points for the,

Order confirmation,

MRP Planning,

Shop floor inventory consumption

and many more........................

Many Experts may include key factor as the master data as MATERIAL MASTER,BOM,ROUTING,

Pl. think beyond this,

your comments will really apprecites,

with regards,

Devendra

[rupesh_brahmankar3 · Accepted solution]

Hi Devendra,

There is no thumb rule to defined it. It depends on the business scenario and practice what are the control and check should be there in system?

• Material master critical fields such as planned delivery time, GR processing time, inhouse prod time, planned delivery time (raw materials), procurement type, under and over delivery, etc should have  been configured as mandatory. This could lead to unauthorized data maintenance, incorrect MIS and inadequate planning.
• Restrict creation of BOM header and components for all material types. This could lead to creation of BOM for incorrect materials also incorrect materials can be used as a component.
• Change number should be mandatory during modification of BOM.
• Change number should be mandatory during creation / modification of routing or recipe.
• Modification of BOM input components or component quantities during production order creation/change and confirmation should be restricted.
• Also ‘over delivery’, ‘under delivery’ and ‘unlimited over delivery’ should not allow to change in production/process order.
• Planned order reference should be mandatory in production/process order for regular orders. And there should be different order type for manual creation of production/process order.
• Backdated order creation should not be allowed.
• Goods receipt should not be possible without issue of input components or confirmation.
• Also exclude material stocks of many non relevant storage locations that are meant for ‘Defective materials’ and ‘Scrap materials’. ‘vendor returns’, ‘customer returns’, etc. This could lead to improper planning.

Regards,

R.Brahmankar

[Former Member · Accepted solution]

Hi rupesh,

your inputs are valuable,

Production planning guys always faced issue with the MATERIAL SHORTAGE,

whetehr it is possible to club such shortages in one transaction?

Whether it is possible to club the consumptions made against BOM Iiems for the FG Product?

Whetehr it is possible to club the changes made in BOM, ROUTING and WORK CENTER in one transaction?

Whether it is possible to view the PRS,PLANNED ORDERS created for the plant run MRP and their requirements details and their pending requiremnt generated in one transaction?

With Regards,

Devendra

[rupesh_brahmankar3 · Accepted solution]

Hi Devendra,

Production planning guys always faced issue with the MATERIAL SHORTAGE,
whetehr it is possible to club such shortages in one transaction?

You can use MDVP is at plant level, MD04 or MD06 it will show you material shortage or MD_STOCK_REQUIREMENTS_LIST_API will help you to develop material shortage report.

Whether it is possible to club the consumptions made against BOM Iiems for the FG Product?

COOIS can help you on it if needed any specific format it can be developed.

Whetehr it is possible to club the changes made in BOM, ROUTING and WORK CENTER in one transaction?

No possible in standard SAP.

Whether it is possible to view the PRS,PLANNED ORDERS created for the plant run MRP and their requirements details and their pending requiremnt generated in one transaction?

MD04 or MD06  or MD_STOCK_REQUIREMENTS_LIST_API will help you to develop report.

Regards,

R,Brahmankar

[former_member184666]

Dear Devendra,

Smooth running of the PP module depends upon the business process requirements and how well the processess are mapped in simple and satnadard way so that user will be able to perform the transaction. Final Goal is user need to do the transaction in SAP system as designed and trained which will benefit for the organization.

Master data:

First criteria for the success of the project is Master data. Master data what SAP PP module is suggesting is all ready being used in different format by almost every organization. I saw even a 50 years old organization is maintained the similar SAP master data right from 50 years back.

Mapping legacy fields perfectly in SAP masters like Material Master, Bill of Materials, Work Center and Routing is the backbone and success of the project. At times there are fields which cannot be mapped but identifying the right non usage fields and mapping the field brings confidence to the users. Always one point to remember is not need to include any Zfields in Masters instead we need to identify the standard fields. Mapping and matching od Master data fields depends on the business process. Some fields are essetial and need to be mapped in Masters else if will have impact in busines process.

Suggest to use ECM. Create Materials, BOM and Routing using Revision level. This will tarck all the masters perfectly with change numbers. One would always like to know what he maintained and changed at different revision levels. Nothing but History tracking.

Confirmation:

Do not use mass confirmation tcodes for regular day to day confirmations. Use tcodes like CO15 / CO11N and in config include restriction to failure of Goods Movement if materials are not issues for stock availability or other reasons. It will avoid for somebody again to look into error records(COGI) and correcting the same which is really a pain area.

Also include restriction to follow the sequence of confirmations through config.

Material Requirement Planning:

Mapping depends on business objective. First identify the materaials which needs to be planned. Then how do you want to plan such materaials is next step. Materials will be of different nature like production required raw materials and low cost materials like consumables. Accordingly MRP type to be selected in Material Master. Based on that planning of the materials will differ.

Define the Finished product demand properly in MD61 if its MTS. Set Up background jobs with specified time and let system run MRP and generate the required proposals.

Shop floor inventory consumption

Again it depends upon how busniess is operated. Business will to use backflushing of the components? Some industries will not. Stores will take control and issue the components with respect to some reference. Order generates reservation and that will be reference for the stores to issue. Practically in production always there is varioation in the cosumption of materials. Excess requirement apart from planned should also be entered in production order seperately. We should have restriction of editing the Production Order BOM qty, stanmdard SAP wil laloow to edit the qty. Based on business operated need to anlyze and make the changes accordingly on orders.

Suggested to have auto GR so that once final operation is confirmed auto of GR will take place for the confirmed qty.

Over and above proper training and documentation with screen shots will bring process awareness to the users.

Thanks & Regards,

Ramagiri

[Former Member]

Hi,

Your inputs are appreciable,

Consultant always try to simplify the system and make user freindly system,

but still management requires Beyond this.

how could SAP refer as 'SYSTEM ACCEPTED PROFESSIONALLY'

Since the management is mostly interested in business revenues and P/L statements,also key interest in identify the losses,Consultants could use their expertise and put real picture and reports to the BIG BOSS so that it become easier to take Business related decisions,

It is the big task for the most consultants.

With regards,

Devendra

[former_member184574]

Hi,

You need to look in to the following things before implementing PP module....

1. Master data: success of your implementation depends on this......from PP point of view...Material master MRP views, work scheduling view, classification view fields have to be set properly........then BOM, Work center/ Resource, Routing/Master Recipe to designed properly....

2. Planning : How the planning is done... make to stock scenario or make to order scenario or combination of both.....manufacturing execution happens based on forecast only or based on customer orders (sales orders) or combination of both.....then all relevant settings for MRP....

3. Execution : Whether to use production orders, process orders or planned orders decided by what type of industry you are working...discrete, REM or process industry.....

Based on the type of industry you need to decide on using Batch Management, Variant Configuration, KANBAN and Process Management functionality.....

Hope this helps....

Thanks

Kumar

[Former Member]

Hi Devendara,

In my understanding I have provided some inputs as below for MRP.

1. 1.      The foremost is to first understand how the demand for the material is flowing into the production plant.  A certain material can be produced based on the below demands
   1. a.      PIR
   2. b.      CIR
   3. c.       Sales order
   4. d.      Consumption based forecast
   5. e.      Time phased reorder
2. 2.      Based on this, the MRP views need to be created. For Ex. Below fields in MRP views of material master can be defined based on the answer for the first question
   1. a.      MRP type,
   2. b.      Fixed lot size
   3. c.       Re-order point
   4. d.      Procurement type
   5. e.      Special procurement type
   6. f. Strategy group
3. 3.      Maintaining the BOM, routing, work center, PRT are all based on production process. So it is very hard to explain these process without the understanding the production scenario. The main area which needs to be concentrated while creating the MD are listed below
   1. a.      BOM – understand the below from the business      
      • Whether the materials can be produced with same set of components always or it is season based.
      • What types of BOM usage and item categories are required?
      • Change management is required or not
      • BOM change history is required or not
      • Sub-items are required or not
   2. b.      Work center -  - understand the below from the business   
      • Standard value keys
      • List of activities
      • Formulas for standard values
      • Capacity
      • Scheduling
      • Shift sequences
   3. c.       Routing - understand the below from the business  
      • How the control key are to be configured
      • No.Of activities
      • Standard text
      • Whether a reference operation set is required or not
      • External operations
      • Component assignments
4. 4.      Plant level parameters of MRP – Scheduling of planned order types, BOM selections, BOM Explosions, Planning horizons etc.
5. 5.      If required think about MRP group, production version, MRP profile etc.

• 6.      How to run MRP – Processing keys

Regards,

Chinna

[Former Member]

Hi,

Master data is the basic requirement,beyond the master data,

If check production variances in detailed, it gives the vast picture of the master data,

1.wether the component consumed,

2.Wether BOM is ok or not as per list and consumption is being as per STD BOM list,

3.Costing is doing well for the raw materials and SFG, FG,

4.Overhead is calculating as per standard mentioned,

5.Any changes in cost for the raw materials ,SFG and FG leads to deatiled analysis.

Also the world class Idle Hours and OEE Reports could be developed with help of Production order confirmation screen or confirmation screen in REM,

it gives picture of the BIG Production losses involved -Down time losses-speed losses-Quality losses-labour hour losses.

it also provides space for the business process reengineering,KAIZEN Activities that leads small changes into process for the better.

With Regards,

Devendra

[Former Member]

Hi,

As per my industry experience, below are the important things from PPC perspective in SAP,

1) For Order Confirmation,

- Before confirmation, ensure that goods issue is done properly if back-flush is not set for the components. This can be check/confirmed by different ways like, documented goods movement in transaction CO03,  goods issue to order by 261 movement type in transaction MB51, on material overview screen of CO03 transaction wherein check quantity withdrawn column for the component item etc. 

- Restrict by over delivery tolerance for confirmation.

- Ensure actual values are entered for activities during confirmation.

- If back-flush is set for the components then ensure that they are displayed in Goods Movement during confirmation.

2) MRP Planning,

- For different business scenarios, automatic MRP planning may differ but as per my view, majority is to set automatic planning ( Transaction MDBT and MD01) for 7 days for the optimal utilization of functionality.

- Ensure that MRP control and Process control parameters are set as per output requirement for business process.

- Segregate different planning materials by creating MRP group, MRP controller, Production Scheduling Profiles, Production Scheduler etc. for better processing and control as well as easy reporting.

- Ensure use of appropriate MRP type for the materials.

- Ensure use of appropriate strategy for the materials.

3) Shop floor inventory control,

- Always issue goods to production order by selecting adopt+details in transaction MB1A as per the standard SAP.  This will restrict UN-necessary issuing of goods to production order.

4) This is important to keep PPC master data like material master, BOM, Work Center, Routing, PRT's for smooth business processing in SAP.

5) Also you can read Best Practices for SAP PP given by SAP to run your business smoothly.

Thanks and Regards,

Narresh

[Former Member]

Hi Naresh,

thanks for your valuable inputs,

Pl. also forward your feedback for  above points I posted,

With Regards,

Devendra

[Former Member]

Hi,

We can check material shortages in CO24 - Missing Parts Info System , along with this there are different reports in standard SAP which can useful like CO09 - Availability Overview , MD09 - Pegged Requirements , MB52, MCPM - Production Order Analysis: Quantities, COOIS and COOISPI - Order Information System.

We can use MCRE - Material Consumption  transaction for BOM items consumption for the FG product.

As per my understanding, it is not possible to club the changes made in BOM, ROUTING and WORK CENTER in one transaction but we can use SAP tables CDHDR - Change document header and CDPOS - change document items. Please correct me if I am wrong.

To view the PR's,Planned orders created for the plant run MRP and their requirements details and their pending requirement generated, we can use COOIS (Production) and COOISPI(Process) transactions by selecting PR's from "List" and by keeping check for Planned Orders. Also by transaction ME5A we can check the PR's created by MRP run by selecting the Creation Indicator "B".

Thanks,

Narresh

[Former Member]

HI,

Let us wait for the PP Expert comments,

Regards,

Devendra

[Former Member]

Hi,

PP experts comments will be appreciated,

Regards,

Devendra