Production Planning

Mixer

Mixer

Snack Bar Line

Form

Bake

Pack

Mixer
Production (200)
Mixer

Finished Goods Warehouse (300)

Raw Material Warehouse (100)

Work Centers for Fitter Snacker

Production Master Data

Company
Code
Valuation
Area
Plant

Work
Center
Material
Master

Routing

Capacity
Planning
Production
Orders

Bill of
Material

Product
Costing

Navigating Material Master Views

Click on tabs to select

Use direction arrows to scroll
Use icon to get list

Material Types
A Material Type is used to classify materials:
Defines material attributes like:
Valuation (value of material as market changes)
Procurement (internal, external or both)
Controls screen sequence and number assignment
Can restrict access using authorization groups
A number of material types are pre-defined
Abbreviations are abbreviations of German terms
Users can create their own material types
Usually best to copy a pre-defined type, then modify

Material Types in Exercises

ROH: Raw material
Externally purchased only, no sales view
Oats, Wheat Germ, Honey, Cinnamon, etc.
HALB: Semifinished Product
No purchase or sales view
Dough for NRG-A and NRG-B bars
FERT: Finished Product
Produced internally, has sales views, no purchasing
views
NRG-A and NRG-B bars

Other Material Types

HAWA:
HIBE:
VERP:
LEER:
KMAT:
ERSA:
DIEN:
NLAG:
UNBW:
FHMI:
WETT:
PROD:
IBAU:

Trading Goods
Operating Supplies
Customer returnable packaging
Empty containers
Configurable material
Spare parts
Services
Non-stock, non-valuated material
Non-valuated, stocked material
Production resources/tools
Competitive products
Product group
Maintenance assembly

Documentation in Material Master

The SAP R/3 system documents all changes
to the material master:

Click for documentation

Documentation in Material Master

Master Data Bill of Material

BOMs are represented as single-level
relationships between a material and its
components and sub-assemblies
BOM for NRG-A

## NRGA
(case)

## Dough NRGA
(lb)

## Oats
(lb)

## Wheat Germ
(lb)

## Cloves
(lb)

## Cinnamon
(lb)

## Canola
(gal)

BOM for
Dough NRG-A

## Nutmeg
(lb)

## Honey
(gal)

## Carob Chips
(lb)

## Raisins
(lb)

## Vit/Min Powder
(lb)

Routings
Routings define the relationship between a
material and the sequence of workcenters
(operations) that are required to produce the
material
Also specifies where sub-components and
sub-assemblies are needed in producing the
material
10

20

30

40

50

60

Functions of Production Orders

(part 1 of 2)
Status Management: Tracking, User-defined status
Scheduling
Calculation of Capacity Requirements (detailed)
Costing/Collection of Costs
Availability Checks (material, capacity, PRT- production
resources and tools)
Printing of Paper Orders/related documents
Assembly drawings and instructions
Inspection instructions
Storage regulations
Material Staging: withdrawal of materials used in
production, e.g. components and sub-assemblies

Functions of Production Orders

(part 2 of 2)
Confirmations: quantities, activities, times
Goods receipt: receipt of completed materials
Period-end closing: Process cost allocation, overhead
costs, surcharges, WIP (work-in-process) calculation,
variance calculation, order settlement
Archiving and retrieval
Many more: rework, serial numbers, as-built, quality
control, etc.

Production Orders capture actual data

costs, dates, etc.

Status Management
(part 1 of 2)
Status Management is one tool that can be used to
manage released production orders
A status can allow, allow with warning, or block a
business transaction
Two status types are available
System status: internal, predefined, fixed number
User status: freely definable, set by user

Status Management
(part 1 of 2)

Status

Status detail

Planned Orders vs. Production

Orders
Planned Orders are for PLANNING
Production Orders are for EXECUTION
Planned Order 3 weeks in future

Planned Orders 2 weeks in future

Planned Orders 1 week in future

Production Orders released today

Planning
Execution

Master Data for Production Orders

Master Data is data that does not change frequently
Master Data for the production order comes from:
Material Master
Bill of Material (BOM)
Work Center
Routing
Production Resources/Tools (PRT)
Materials like gages, fixtures, test equipment
Can also be items like drill bits that can be
consumed in production but arent consumed
INTO the product
Most Production Order data comes from BOM and
Routing

Archiving &
Deletion

Order Request
1

16

Order
settlement

Order Creation
2

Availability
Checks

15

Variance
Calculation

Goods Receipt
WIP
Determination

Production
Order
Cycle

14

13

5
6

12
7

11

Confirmation

10

Upload from
PDC system Material withdrawal
posting

Machine
Reservation
Order Release
Download to
PDC system
Print Order

Material staging

Routing Selection
Different routings can be selected for a product
depending on a number of criteria like:
Raw material used
Lot size
Product features/configurations (variants)
A complicated, automatic selection process
can be configured

Bill of Material (BOM)

The system selects the FIRST Valid BOM it
finds
Validity can depend on:
Date (engineering changes)
Customer
Serial number

Material
Material

Material

Material Assignment
Assigned via BOM:
All materials assigned to
first operation

OP
OP
OP
OP
OP
..
0010 0020 0030
0080 0090

Assigned via Routing:

Materials can be assigned
to specific operations

Material

Material

OP
OP
OP
OP
OP
..
0010 0020 0030
0080 0090

Material