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Consulting

Transforming Enterprises

Title Version Author Reviewed By Date

PP 1.0

Master Data

Anupam Sharma

09.08.2011

Project XXXX
1. 2. 4. QUALITY CHECK ................................................................................................................ 3 BLUEPRINT AGREEMENT ................................................................................................. 3 OVERVIEW: MASTER DATA .............................................................................................. 4 4.1
4.1.1

3. LEGEND ................................................................................................................................. 3

Material Master................................................................................................................ 4
Business Process Details ................................................................................................................ 5

4.2
4.2.1

Bill of Material ................................................................................................................. 5


Business Process Details ............................................................................................................ 6

4.3
4.3.1

Resource/Work centre ...................................................................................................... 6


Business Process Details .............................................................................................................. 7

4.4
4.4.1

Master Recipe: ................................................................................................................... 7


Business Process Details ............................................................................................................. 7

4.5

Production version .............................................................................................................. 7

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1. QUALITY CHECK
Version 1.0 Date Validated by Date Signature

2. BLUEPRINT AGREEMENT
Signing this document records your agreement to the contents of the Blueprint, and confirms that the remainder of the project can proceed. Name Position Date Signature

3. LEGEND

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The following describes the symbols used in the process map:

High-level process activity. A more detailed process map is provided in the document to describe the activity

Decision

Activity step

Document

System

Continuation of the process map to a different page

4. OVERVIEW: MASTER DATA

4.1

Material Master
This master data helps to identify the materials that are used in Production Planning and Execution. All materials that are either produced or consumed in production

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process will be activated for MRP and Shop Floor control and relevant data should be entered based on the material type.

4.1.1

Business Process Details All materials that are taking part in the production process, Production Planning data for the materials should be maintained and relevant Material Requirements Planning Type, Planning Strategy group etc are to be defined in the Material Master. The MRP view of the material master primarily contains the control parameters that govern the material requirement planning throughout the logistics supply chain. In the material master, MRP views contain various information like MRP Type (Type of Planning i.e. MRP, Reorder Point Planning etc.), MRP Controller (Person Responsible for Planning), Lot Sizing Procedure (Process to determine the Qty. of Material to be Produced or Procured), Procurement Type (Internal or External procurement), Scheduling data (For Rough Cut Scheduling), Planning Strategy (which govern Production Process), Availability Check controls, Dependent requirement calculation procedure etc. The work Scheduling view of the Material master data contains Shop Floor Control parameters, Production Tolerances and Lot size dependent & Lot Size Independent In-house production time. All Production Planning data is maintained at the plant level. This allows controlling the PP processes for the plant of a company in different ways. PP-specific data in the material master plays a part in: Managing MRP information for materials Managing Production Controls for materials Planning for Procurement proposals and Planning Strategy To control PP activities following data are defined MRP Data MRP Type MRP Controller Lot Sizing Procedure Procurement Type Scheduling Margin Key Planning Strategy Group Availability Check Control

Work Scheduling Data Delivery tolerances Lot-Size Dependent In-House production time Lot-Size Independent In-House production time Production Scheduler

4.2

Bill of Material

A bill of material is a complete, formally structured list of the components that make up a product or assembly. The list contains the object number of each component, together with the quantity and unit of measure.

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4.2.1 Business Process Details BOM s are used in their different forms in various situations where a finished product is assembled from several component parts or materials. Depending on the industry sector, they can also be called material list or lists of ingredients and so on. They contain important basic data for numerous areas of a company, for example: MRP (Material requirements Planning) Material provisions for production Product costing Plant Maintenance

Structure of a BOM:

The data stored in bills of material serves as a basis for production planning activities such as: A design department can base its work on bills of material. A material requirements planning (MRP) department explodes bills of material on a certain date to calculate cost-effective order quantities for materials. A work scheduling department uses bills of material as a basis for operation planning and production control. A production order management department uses bills of material to plan the provision of materials. The data stored in bills of material is also used in other activities in a company such as: Reservation and goods issue : As an aid to data entry Product costing : To calculate the costs of materials required for a specific product

4.3

Resource/Work centre
This master data helps to identify the production centers that are used in Production Planning and Execution. This master data is used in Master recipe and Production/Process orders to identify which machines / production centers are being used in manufacturing the materials attached in the Master recipe / Production( Process ) order. The commonly work centers/resources in cement industry are as follows:

S NO. 1 2 3 4

RESOURCE/WORK CENTRE CRUSHER RAW MILL KILN GRINDING MILL

CODING

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5 6 7 8
4.3.1

BLENDER COAL MILL PACKAGING STATION CLASSIFIER


Business Process Details A Resource is an organizational unit where a work step is carried out, producing an output. Data in resource is used for : Scheduling: Operating times and formulas are entered in the resource, so that the duration of an operation can be calculated. Capacity Planning: The available capacity and formulas for calculating capacity requirements are entered in the resource Costing: Formulas are entered in the resource, so that the costs of an operation can be calculated. A resource is also assigned to a cost centre. Capacity Requirements Planning : Formulas for calculating capacity requirements for an operation are maintained in resource Simplification of Operation Maintenance: Various default values like Control key, Standard Values etc. are maintained for the operation in the resource.

4.4

Master Recipe:

A master recipe is a description of which operations (process steps) have to be carried out and in which sequence to produce a material (product). In addition to the information about the operations and the sequence in which they are carried out, a master recipe also contains details about the resource at which they are carried out and the components required at each step. 4.4.1 Business Process Details

A master recipe is used as a source for creating a production order by copying. A master recipe is composed of a header and one or more operations. The header contains data that is valid for the whole master recipe. A sequence is a series of operations. Operations describe individual process steps, which are carried out during production. A master recipe is identified by its group and group counter. A master recipe is used to produce output materials (finished, semi finished products). It contains operations and data on the corresponding work centers, material allocations, operation texts and standard values for operations. In the SAP System, master recipes have the same basic structure as master recipes, inspection plans, maintenance task lists. As a generic term for these objects, SAP has introduced the term "task list". A master recipe is created in order to produce substances on a plant line. A master recipe Describes the activities necessary for production Allocates resource and materials to the master recipe

4.5

Production version
Production version represents the combination of master recipe & BOM can be created if required. Many of the Products are having an alternate BOM and in some cases alternate master recipe too.

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In this case it is mandatory to have production version maintained so that at the time of order creation, user can select the suitable production version so that the relevant BOM and master recipe gets copied in to the order.. It is a prerequisite to create production versions for products, i.e. combination of BOM & Master recipe.

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