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Solution Building Block Document

Altra Global SAP S4 HANA Project


PTS – MTS Production with Variant Configuration – 21D

Version 2.0
01/04/19
Document Meta Data

Stream Name Project Name


Plan to Supply Altra Global SAP S/4 Hana

Capability SME Owner(s)


Production Planning Andy Zielaskowski

Revision History

Version Date Description Author


1.0 12/12/18 Initial Draft Sridhar Palepu
2.0 01/04/19 Review/Updated Liza Al-Rajhi
2.0 01/09/19 Review/Updated Madhavan Rajan
2.0 QA Review

Document Status

Review Status Final

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Contents

1. Introduction / Purpose.......................................................................................................................... 4
2. Assumptions .......................................................................................................................................... 4
3. Solution requirements .......................................................................................................................... 4
3.1. Capabilities .................................................................................................................................... 4
3.2. Value KPIs ...................................................................................................................................... 5
4. Process Flow Diagram & SAP Transactional Steps ................................................................................ 6
4.1. Process Flow.................................................................................................................................. 6
4.2 SAP Transactional Steps........................................................................................................................... 6
5. Pre-delivered Solution Components ..................................................................................................... 7
5.1. Pre-delivered content (e.g. Best Practices)................................................................................... 7
6. Project Specific Solution Components .................................................................................................. 8
6.1. Best Practices (modifications) ....................................................................................................... 8
6.2. Process Control Requirements ..................................................................................................... 8
6.3. Configuration Considerations ....................................................................................................... 8
6.3.1. MRP Controllers .................................................................................................................... 8
6.3.2. Standard Value Key ............................................................................................................... 8
6.4. Forms, Reports, Interfaces, Conversions, Enhancements, Workflow .......................................... 8
6.4.1. Forms .................................................................................................................................... 8
6.4.2. Reports .................................................................................................................................. 8
6.4.3. Interfaces .............................................................................................................................. 9
6.4.4. Conversions ........................................................................................................................... 9
6.4.5. Enhancements....................................................................................................................... 9
6.4.6. Workflow............................................................................................................................... 9
7. Security considerations ......................................................................................................................... 9
7.1. Organizational Constraints............................................................................................................ 9
7.2. Standard Roles ............................................................................................................................ 10
7.3. Customized Roles ........................................................................................................................ 10
8. Out of Scope........................................................................................................................................ 10
9. Appendices .......................................................................................................................................... 11
10. Sign-off ............................................................................................................................................ 11

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1. Introduction / Purpose
This Solution Building Block (SBB) document enumerates the business requirements associated with best
practice of Make to Stock (MTS) Production with Variant Configuration. This scope item shows the Make-
to-Stock Production with Variant Configuration in which Advanced Variant Configuration enables efficient
state-of-the-art configuration for configurable products variants that reflect common definitions of a
configurable material. The material variant is defined as a Bill of Material (BOM) where the components
meet certain criteria. Initially, this material variant is produced and put into stock as later sales of it are
anticipated by collection of Planned-Independent Requirements (PIRs). When a customer orders this
Variant of the Finished Product where the characteristics of the components match the material variant,
the finished product is taken directly from stock as production had already been completed based on PIRs.
The sales price calculation is then based on the characteristics of the material variant. Since the material
variant is available on stock, the finished product is directly delivered. The process finishes with the billing
of the delivered Finished Product.

2. Assumptions
The following assumptions were made with respect to the design of this business process.

 The Material Master for the Configurable Material (KMAT Material) has been maintained.
 Standard variants of a configurable material will be defined as material variants.
 Workcenter, Bill of Materials, Routings, and Production versions are defined for the material
variant.
 Material Requirements Planning (MRP) will be used to generate supply elements in response to
customer demand. These supply elements will drive dependent demand into lower levels of the
Bill of Material (BOM) and create capacity loads on the corresponding work centers via the
Routing’s list of operations.
 Production Orders will be used to identify specific components and tasks for both normal
manufacturing and rework tasks. Users will confirm time spent and materials consumed to
production orders. These costs for labor time and issued components costs will be settled to the
appropriate WBS elements.
 Quality Management (QM) will be used. Inspection steps may be assigned to tasks within the
production order as well as linked to the completion (goods receipt) of the same.
 Inventory Management (IM) will be used. Stock levels of most components will be tracked at a
storage location level as one of three inventory types (unrestricted, inspection, or blocked) and
assigned to one of several stock categories (e.g., project, vendor-consigned, customer-consigned,
out to vendor).
 Serial Number management will be used on those products that require traceability.

3. Solution requirements
3.1. Capabilities
Make-to-Stock Production with Variant Configuration – This process enables production planning and
execution in a make-to-stock scenario where the common material variants for a configurable material is
planned and produced in advance, anticipating a future sale for the produced variant. A configurable

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material and a configurable BOM is defined as a pre-requisite. Standard material variants are created to
which the configurable material and configurable BOM is linked. The material variant is configured right
within the product master using pre-defined characteristic values that define the material variant.
Planning starts in the form of creating planned independent requirements for the material variants. Multi-
level MRP run creates planned orders for in-house produced products and purchase requisitions for
externally procured items. The dependency procedures defined in the BOM and Routings will determine
the lower level components / sub-assemblies required and will also determine the routing steps required
to manufacture the material variant.
Production order execution is carried out as per the steps defined in the Altra SBB for “PTS-MTS
Production – Discrete Manufacturing-BJ5”. Sales delivery processing and customer billing steps are
carried out as per the steps defined in Altra SBB “OTC-Sell From Stock-BD9”.

Key process steps:

1. Create Planned Independent Requirements for material variant


2. Execute multi-level Material Requirements Planning (MRP)
3. Monitor material coverage
4. Create Production order
5. Release Production Order for Parts Production
6. Pick Components
7. Confirm routing activities/final confirmation
8. Post Goods Receipt for Production Order
9. Create Sales order for configurable material and assign customer specified characteristics.
10. Choose an appropriate material variant and carry out ATP.
11. Create Delivery
12. Execute Picking
13. Post Goods Issue
14. Release Billing
15. Create milestone Invoice and Send to Customer
16. Post Milestone Invoice
17. Create closing Invoice and Send to Customer
18. Post Closing Invoice

Steps #9 to #18 above are covered in detail in Altra SBB “OTC-Sell From Stock-BD9”.

3.2. Value KPIs

1. Plan vs Target vs Actual – Quantity variance


2. Plan vs Target vs Actual – Cost variance

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4. Process Flow Diagram & SAP Transactional Steps
4.1. Process Flow

4.2 SAP Transactional Steps.


4.2.1 Select a Material Variant that is assigned to a Configurable Material and manufactured with
Make to Stock Strategy 40 in MRP 3 view.

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4.2.2 Create Sales Order. Run MRP and capture Planned Orders and convert them to Production
Orders.

5. Pre-delivered Solution Components


5.1. Pre-delivered content (e.g. Best Practices)
The following Pre-delivered Solution Components (listed alphanumerically by component ID) are
applicable to this business process:

Make-to-Stock Production with Variant Configuration (21D)

Make-to-Stock Production with Variant Configuration (21D)


The link above will open the Best Practice procedure for Make-to-Stock Production - Discrete Manufacturing (BJ5)

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The following Pre-delivered Master Data elements are relevant to this business process:

 BNJ (Create Production Work Center)


 BNK (Create Production Bill of Material)
 BNL (Create Routing)
 BNR (Create Product Master of type “Raw Material”)
 BNS (Create Product Master of type “Semi-Finished Good”)
 BNT (Create Product Master of type “Finished Good”)

6. Project Specific Solution Components


6.1. Best Practices (modifications)
No significant modifications to the pre-delivered best practices have been identified at this point.

6.2. Process Control Requirements


No significant modifications to the pre-delivered best practices have been identified at this point.

6.3. Configuration Considerations


Minor configuration changes may be needed though not all will be known at the time when this
document is published.

6.3.1. MRP Controllers


Create MRP Controllers to match Altra Material Planners.

6.3.2. Standard Value Key


Create a standard value key to include only labor.

6.4. Forms, Reports, Interfaces, Conversions, Enhancements, Workflow


6.4.1. Forms
There are no forms relevant to this SBB.

Name Description Complexity Specification

6.4.2. Reports
Standard reports will be utilized to the extent possible. No custom reports have been identified
for this SBB.

Name Description Complexity Specification

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6.4.3. Interfaces
There are no interfaces relevant to this SBB.

Name Description Complexity Specification


None

6.4.4. Conversions
The following conversions are expected for this SBB. Some of these data elements may be
covered in other SBBs. Depending on the volume of data, some of these data elements may not
need to have a conversion object. In these cases, the data will be created manually.

Name Description Complexity Specification


Material Master Material Master Medium
Bill of Materials Bill of Materials Medium
Work Center Work Center Low
Routing Routing Medium
Production Production Version Low
Version

6.4.5. Enhancements
There are no enhancements relevant to this SBB.

Name Description Complexity Specification


None

6.4.6. Workflow
There are no workflow objects relevant to this SBB.

Name Description Complexity Specification


None

7. Security considerations
All users in the SAP system are registered in the same database. System permissions as defined for the
organization need to assign to users by ALTRA staff prior to go live. This section describes specific
organizational security constraints (permissions) related to this business process. It further lists standard
and/or customized roles that enable these relevant permissions before they are assigned to the users.

7.1. Organizational Constraints


Due to the limited organizational scope of ALTRA there are no specific constraints are identified at
this time.

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7.2. Standard Roles
The following standard Fiori roles may be required to execute the process steps defined in this SBB.
Role Technical Name Comment
PP Basic Data Processing ZSC_PP_BD_PROCESSING Single role
PP Basic Data Display ZSD_PP_BD_DISPLAY Single role
Manage Planned Orders ZSC_PP_MRP_PLANNED_ORDER Single role
Manage MRP Master
ZSC_PP_MRP_MASTER_DATA Single role
Data
MRP Evaluations ZSC_PP_MRP_EVALUATIONS Single role
Shop Floor Inventory
ZSC_PP_SFC_MAT_MANAGEMENT Single role
Management
Error Handling ZSC_PP_SFC_ORDER_EXCEPTIONS Single role
Shop Floor Information
ZSC_PP_SFC_EVALUATIONS Single role
Analysis
Production
ZSC_PP_SFC_CONFIRMATIONS Single role
Confirmations
Production Goods
ZSC_PP_SFC_GOODS_MVT Single role
Movements
Variant Configuration
ZSC_PP_VC_MASTER_DATA Single role
Master Data Change
Variant Configuration
ZSD_PP_VC_MASTER_DATA Single role
Master Data Display
Display shop floor data ZSD_PP_SFC_DISPLAY Single role
PP Administrator ZCC:PP_ADMINISTRATOR Composite Role
MRP Controller ZCC:PP_MRP_CONTROLLER Composite Role
Production Supervisor ZCC:PP_PRODUCTION_SUPERVISOR Composite Role
Production Operator ZCC:PP_PRODUCTION_OPERATOR Composite Role
Design Engineer ZCC:PP_DESIGN_ENGINEER Composite Role

7.3. Customized Roles


At this time, no customized roles are expected.

8. Out of Scope
This document describes the full scope of this business process. Anything not specifically described
within the content is considered out of scope.

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9. Appendices
No appendices are included at this time.

10. Sign-off
I/We certify that this document completely and accurately reflects the requirements for this Solution
Building Block Document. I/We understand that anything not explicitly mentioned in this document is
considered out of scope for the project.

Project Role Name/Signature Date

Program Manager: Dan Hughes /


Client Project Manager: Meg LeSuer /
Business Process Owner(s) Andy Zielaskowski /
Consultant(s): Sridhar Palepu /
Illumiti Project Manager: Liza Al-Rajhi /
Illumiti Solution Architect: Kristina Gordon /

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