ISBN-10:
1493214306
ISBN-13:
9781493214303
Pub. Date:
06/28/2016
Publisher:
Rheinwerk Publishing, Inc.
Production Planning and Control with SAP ERP / Edition 2

Production Planning and Control with SAP ERP / Edition 2

by Jawad Akhtar

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Overview

Step up your SAP PP game! Learn how to configure SAP ERP Production Planning for discrete, process, and repetitive manufacturing and master BOM status definitions, process message characteristics, and master data. Dive into SAP PP workflows and use Process Management, release production orders, and create planning tables. Covering everything from S&OP and MRP to SAP Demand Management and the Early Warning System, this book will help you get your production process to maximum efficiency!

Configuration
Get step-by-step instructions for configuring SAP PP, from master data shared by all manufacturing types to specific settings and control keys for discrete, process, and repetitive manufacturing.

Workflow Tools
Learn to use sales and operations planning, material requirements planning, SAP Demand Management, and long-term planning throughout your production workflow.

Reporting and Optimization
Get more out of your production system with capacity requirements planning, co-products, by-products, and more. Then evaluate and monitor your system using built-in reports and the Early Warning System.

Highlights:

  • Discrete, process, and repetitive manufacturing
  • Configuration
  • XSteps
  • Sales and operations planning (S&OP)
  • Material requirements planning (MRP)
  • SAP Demand Management
  • Long-term planning (LTP)
  • Special procurement types
  • Capacity requirements planning (CRP)
  • Digital signatures
  • Early Warning System (EWS)

Product Details

ISBN-13: 9781493214303
Publisher: Rheinwerk Publishing, Inc.
Publication date: 06/28/2016
Edition description: 2nd Enlarged ed.
Pages: 940
Sales rank: 728,441
Product dimensions: 7.20(w) x 9.30(h) x 1.80(d)

About the Author

Jawad Akhtar works as the SAP Leader for Business Sales and Delivery at IBM Pakistan. He earned a chemical engineering degree from Missouri University of Science and Technology (USA) in 1996. He has more than 18 years of professional experience and has completed several large-scale SAP implementations and rollout lifecycles. He has led large teams in his roles as an SAP integration manager and SAP project manager, and has also been proactively involved in business development and solution architect roles. He is the technical advisor to SAPexperts and is a prolific contributor to SearchSAP, where he shares his views on logistics, supply chain management (SCM), product lifecycle management (PLM), and project management.

You can view his profile on LinkedIn at http://pk.linkedin.com/in/jawadakhtar. You can also contact Jawad via email at jawad.akhtar@live.com or Twitter @jawadahl.

Table of Contents

... Acknowledgments ... 25

1 ... Production Planning Core Concepts ... 27

1 ... Introduction ... 29


... Goals of This Book ... 29


... Target Audience ... 30


... Structure and Content ... 31

... Organizational Structures in SAP ERP ... 35


... Breaking Down the Structure into Units ... 35


... Production Planning in SAP ERP ... 44


... Product Costing ... 59


... SAP Calendar ... 61


... Summary ... 66


... Configuration Specifics for Manufacturing Types ... 67

... Configuration Basics of Discrete Manufacturing ... 69


3.1 ... Material Master ... 70


3.2 ... Bill of Materials ... 72


3.3 ... Work Center ... 78


3.4 ... Routing ... 87


3.5 ... Production Order Creation ... 89


3.6 ... Order Type-Dependent Plant Parameters ... 94


3.7 ... Production Scheduling Profile ... 99


3.8 ... Default Values for the Generation of Operations ... 101


3.9 ... Availability Check ... 102


3.10 ... Stock and Batch Determination ... 108


3.11 ... Scheduling ... 108


3.12 ... Reduction Strategy ... 114


3.13 ... Confirmation ... 115


3.14 ... Reason for Variances ... 124


3.15 ... Trigger Points ... 125


3.16 ... Define Print Control ... 126


3.17 ... Background Jobs ... 127


3.18 ... Process Integration ... 128


3.19 ... Summary ... 128

... Configuration Basics of Process Manufacturing ... 129


4.1 ... Master Data in Process Industries ... 130


4.2 ... Order Type-Dependent Parameters ... 134


4.3 ... Production Scheduling Profile ... 136


4.4 ... Process Management ... 138


4.5 ... Process Messages ... 143


4.6 ... Process Instruction Category ... 150


4.7 ... Control Recipe/Process Instruction Sheets ... 164


4.8 ... Background Jobs ... 169


4.9 ... Process Management Configuration: At a Glance ... 171


4.10 ... Process Management: Configuration and Implementation Roadmap ... 172


4.11 ... Process Manufacturing Cockpit ... 174


4.12 ... Summary ... 177

... Configuration Basics of Repetitive Manufacturing ... 179


5.1 ... Repetitive Manufacturing Profile ... 180


5.2 ... Scheduling Planned Orders ... 192


5.3 ... Display ... 193


5.4 ... Material Staging ... 195


5.5 ... Global Settings for Confirmation and the Logistics Information System ... 196


5.6 ... Operational Methods Sheet ... 197


5.7 ... Summary ... 198

3 ... Production Planning Workflow by Production Type ... 199

... Production Planning for Discrete Manufacturing ... 201


6.1 ... Process Overview ... 202


6.2 ... Master Data ... 203


6.3 ... Production Order Management ... 243


6.4 ... Release Production Order ... 265


6.5 ... Printing ... 268


6.6 ... Material Withdrawal ... 271


6.7 ... Confirmation ... 278


6.8 ... Goods Receipt ... 285


6.9 ... Postprocessing ... 288


6.10 ... Settlement and Completion ... 292


6.11 ... Production Order Batch Traceability Using Work in Process Batches ... 293


6.12 ... Additional Functions and Information Systems ... 304


6.13 ... Summary ... 309

... Production Planning for Process Industries ... 311


7.1 ... Process Manufacturing Overview ... 312


7.2 ... Master Data in Process Manufacturing ... 314


7.3 ... Process Management ... 327


7.4 ... Process Order Execution ... 341


7.5 ... Process Management in Action ... 343


7.6 ... Execution Steps (XSteps) ... 354


7.7 ... Process Manufacturing Cockpit ... 367


7.8 ... Process Messages Evaluation ... 368


7.9 ... Miscellaneous Cross-Manufacturing Topics ... 370


7.10 ... Summary ... 371

... Production Planning for Repetitive Manufacturing ... 373


8.1 ... Overview ... 374


8.2 ... Repetitive Manufacturing Master Data ... 377


8.3 ... Material Requirements Planning in Repetitive Manufacturing ... 400


8.4 ... Collective Availability Check ... 404


8.5 ... Operational Method Sheet ... 405


8.6 ... Planning Table in Repetitive Manufacturing ... 406


8.7 ... Material Staging ... 414


8.8 ... Production List ... 419


8.9 ... Confirmation ... 421


8.10 ... Reversals and Scrap ... 430


8.11 ... Collective Confirmation ... 435


8.12 ... Costing Activities (Cost Object Controlling) ... 436


8.13 ... Reporting ... 437


8.14 ... Summary ... 438

4 ... Production Planning Workflow Tools ... 441

... Sales and Operations Planning ... 443


9.1 ... Standard Sales and Operations Planning ... 444


9.2 ... Flexible Planning ... 467


9.3 ... Maintaining Version Management ... 492


9.4 ... Forecasting ... 495


9.5 ... Rough-Cut Planning Profile ... 502


9.6 ... Events ... 507


9.7 ... Mass Processing in Sales and Operations Planning ... 513


9.8 ... Standard Analysis in Flexible Planning ... 517


9.9 ... Summary ... 520

... SAP Demand Management ... 521


10.1 ... Planning Strategy ... 522


10.2 ... Planned Independent Requirements ... 531


10.3 ... Customer Independent Requirements ... 536


10.4 ... Summary ... 544

... Material Requirements Planning ... 545


11.1 ... Process Overview ... 546


11.2 ... Scrap ... 561


11.3 ... Safety Stock ... 564


11.4 ... Material Requirements Planning Procedures ... 567


11.5 ... Consumption-Based Planning ... 572


11.6 ... Forecast-Based Consumption Planning ... 577


11.7 ... Types of Planning Runs ... 581


11.8 ... Scheduling ... 585


11.9 ... Procurement Proposals ... 591


11.10 ... Executing Material Requirements Planning ... 597


11.11 ... Configuration Settings for Material Requirements Planning ... 605


11.12 ... Material Requirements Planning Run Analysis ... 610


11.13 ... Planning Calendar ... 621


11.14 ... Material Requirements Planning Areas ... 623


11.15 ... Summary ... 631

... Long-Term Planning ... 633


12.1 ... Long-Term Planning Master Data and Planning Data ... 634


12.2 ... Long-Term Planning: Business Process ... 639


12.3 ... Further Options in Long-Term Planning ... 647


12.4 ... Evaluate Information Systems for Long-Term Planning ... 654


12.5 ... Summary ... 659

5 ... Optimizing Production Planning ... 661

... Special Procurement Types ... 663


13.1 ... Overview ... 664


13.2 ... Phantom Assembly ... 666


13.3 ... Direct Production ... 667


13.4 ... Direct Procurement ... 672


13.5 ... Stock Transfer (Interplant Transfer) ... 676


13.6 ... Withdrawal from Alternate Plant ... 679


13.7 ... Production in Alternate Plant ... 681


13.8 ... Subcontracting ... 683


13.9 ... Consignment ... 688


13.10 ... Pipeline Material ... 691


13.11 ... Summary ... 691

... Capacity Requirements Planning ... 693


14.1 ... Process Overview ... 694


14.2 ... Capacity Requirements and Capacity Evaluation ... 696


14.3 ... Finite Scheduling ... 711


14.4 ... Dispatching ... 713


14.5 ... Capacity Planning Table ... 730


14.6 ... Summary ... 737

... Classification ... 739


15.1 ... Classification System ... 740


15.2 ... Assigning the Material Class to the Material Master ... 746


15.3 ... Finding Objects in Classes ... 749


15.4 ... Assigning an Equipment Class to Equipment ... 751


15.5 ... Summary ... 754

... Co-Products and By-Products in Production Processes ... 755


16.1 ... Check in Material Master ... 757


16.2 ... Bill of Materials ... 760


16.3 ... Process Order ... 762


16.4 ... Goods Issue ... 764


16.5 ... Confirmation ... 766


16.6 ... Goods Receipt ... 768


16.7 ... Documented Goods Movement ... 770


16.8 ... Cost Analysis ... 771


16.9 ... Summary ... 773

... Digital Signature ... 775


17.1 ... Configuration Steps to Set Up a Digital Signature ... 776


17.2 ... Digital Signature in Action ... 783


17.3 ... Digital Signature Logs ... 788


17.4 ... Application of Digital Signature in SAP ERP Components ... 789


17.5 ... Summary ... 791

6 ... Monitoring and Evaluation ... 793

... Early Warning System ... 795


18.1 ... Overview ... 795


18.2 ... Exceptions ... 797


18.3 ... Set Up Periodic Analysis ... 804


18.4 ... Schedule an Early Warning System ... 806


18.5 ... Early Warning System in Action ... 808


18.6 ... Exception Analysis ... 811


18.7 ... Summary ... 814

... Reporting in SAP ... 815


19.1 ... The Basics of Reporting ... 816


19.2 ... Order Information System ... 818


19.3 ... Missing Parts Information System ... 833


19.4 ... Standard Analysis Reports ... 834


19.5 ... Data Browser ... 843


19.6 ... QuickViewer ... 848


19.7 ... SAP Query ... 852


19.8 ... Assign a Transaction Code to a Query ... 855


19.9 ... Summary ... 856

... Integration of Production Planning with Logistics Functions ... 857


20.1 ... Integration Prerequisites ... 858


20.2 ... Integration Aspects of Production Planning with Quality Management ... 860


20.3 ... Integration of Production Planning with Materials Management ... 875


20.4 ... Integration of Production Planning with Sales and Distribution (Make-to-Order Production) ... 882


20.5 ... Integration of Production Planning with Sales and Distribution (Assembly Processing) ... 886


20.6 ... Integration of Production Planning with Project System (Engineer-to-Order Production) ... 888


20.7 ... Integration of Production Planning with Plant Maintenance ... 894


20.8 ... Integration of Production Planning with SAP Manufacturing Execution ... 894


20.9 ... Integration of Production Planning with SAP Manufacturing Integration and Intelligence ... 895


20.10 ... Summary ... 896

... Appendices ... 897

A ... Comparison Table of Production Types ... 899

B ... Glossary ... 905

C ... The Author ... 925

... Index ... 927


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