Sap pp shop floor control configuration

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Sap pp shop floor control configuration

  1. 1. A Step-by-Step Guide to the SAP PP Shop Floor Control ConfigurationsTable of ContentsObjective ........................................................................................................................... 4IMG Menu – The Starting Point ......................................................................................... 5An Overview of the SAP Production Orders ...................................................................... 6The Bills of Materials in relation to the Shop Floor Production Order ................................ 7Start of the SAP Production Order Configurations ............................................................ 9Define the Production Order Types ................................................................................... 9How to configure the Production Order User Status?...................................................... 12Where-is the Production Order Type used? .................................................................... 16Define the Production Order Type-dependent Parameters ............................................. 16Define Checking Control.................................................................................................. 24Define Confirmation Parameters ..................................................................................... 25Define Scheduling Parameters for Production Orders..................................................... 30Define Number Range..................................................................................................... 33Define selection profiles for the Order Information System ............................................. 35Where-is the Selection Profile used?............................................................................... 36Define the Production Operations Control key ................................................................ 37Where-is the Control key used? ...................................................................................... 38Define formula parameters for Work Center.................................................................... 39Where-is the Work Center Formula Used?...................................................................... 42Define the Production Scheduling Profile ........................................................................ 42Define Production Scheduler........................................................................................... 45Where-is the Production Scheduling Profile and Production Scheduler Used?............... 45Define User Exits Selection ............................................................................................. 46Select Routing Automatically ........................................................................................... 47Where do you define the Usage and Status? .................................................................. 48Define Default Values If No Routing Exists ..................................................................... 48Define Priorities for BOM Usages.................................................................................... 50Define Applications for BOM Explode.............................................................................. 50Define Alternative Determination for Production.............................................................. 52Define Checking Group ................................................................................................... 53Define Checking Rule...................................................................................................... 54Define Scope of Check.................................................................................................... 54Define Checking Rule for Backorder Processing............................................................. 56Specify Scheduling Type ................................................................................................. 57Define Standard Value Keys ........................................................................................... 58Where-is the Standard Value Key used?......................................................................... 60Define Scheduling Margin Key ........................................................................................ 60Define Capacity Categories............................................................................................. 61Where-is Capacity Categories used? .............................................................................. 62Define Single Screen Entry for Time Ticket Confirmations.............................................. 63Maintain Language-Dependent Texts.............................................................................. 66Define Reasons for Variances for Production Scrap ....................................................... 67Where-is the Production Reason Code used? ................................................................ 68Define Print Control for Shop Floor Papers ..................................................................... 68Preparing the Initial Implementation of the PP Shop Floor Control Module..................... 72Static versus dynamic data conversion ........................................................................... 73A Sample Note to users regarding the Uncompleted Production Orders......................... 73@ www.sap-img.com Page 1 of 79 SAP Version 4.6c
  2. 2. A Step-by-Step Guide to the SAP PP Shop Floor Control ConfigurationsAppendix A: The Production Order Status Business Process Flow................................. 74Appendix B: How to make enquiry on Open Production Orders?.................................... 76Appendix C: What is Backflushing and Where is the Indicator Set?................................ 77@ www.sap-img.com Page 2 of 79 SAP Version 4.6c
  3. 3. A Step-by-Step Guide to the SAP PP Shop Floor Control ConfigurationsCopyright© 2004 www.sap-img.com. All rights reserved.www.sap-img.com makes no warranties or representations with respect to the content hereof andspecifically disclaims any implied warranties of merchantability or fitness for any particular purpose.www.sap-img.com assumes no responsibility for any errors that may appear in this document. Theinformation contained in this document is subject to change without notice.www.sap-img.com reserves the right to make any such changes without obligation to notify any person ofsuch revision or changes.www.sap-img.com makes no commitment to keep the information contained herein up to date.TrademarksABAP/4 is a registered trademark of SAP AG.SAP, R/2, R/3, SAPoffice, Smart Forms, SAPscript, SAP EarlyWatch, and SAP Business Workflow areregistered trademark of SAP AG.All other products mentioned in this documentation are registered or unregistered trademarks of theirrespective companies.@ www.sap-img.com Page 3 of 79 SAP Version 4.6c
  4. 4. A Step-by-Step Guide to the SAP PP Shop Floor Control ConfigurationsObjectiveThe objective of this paper is to provide the SAP PP consultant with a step-by-step guidesat configuring the SAP PP Shop Floor Control module. It is structure in the form of how-to-do configurations method.When you do the SAP configuration, sequence is not really important as long as allthe PP Shop Floor Control modules Features that need to be used have beenconfigured.Notes:Initial IMG Action : Required (this are dynamic data which are unique to the company)Initial IMG Action : Usually Not required (it depends on the customer requirement)Initial IMG Action : Not required (normally this kind of configuration is quite static, mostof the customer will accept the SAP default and may request for changes after going livefor a period of time)@ www.sap-img.com Page 4 of 79 SAP Version 4.6c
  5. 5. A Step-by-Step Guide to the SAP PP Shop Floor Control ConfigurationsIMG Menu – The Starting PointBefore doing any SAP Configuration, all SAP consultants MUST be aware of thetransaction SPRO. This transaction code is the heart of the whole SAP configuration.Click the button and you will be shown all the configuration tree for thevarious SAP modules like SD, PP, FI, CO etc.Transaction SPROThe SAP IMG configuration tree for all the modules@ www.sap-img.com Page 5 of 79 SAP Version 4.6c
  6. 6. A Step-by-Step Guide to the SAP PP Shop Floor Control ConfigurationsAn Overview of the SAP Production OrdersAs the name implies, Production Orders is a work processes that a company uses toproduced the Finished Goods that the Customer Need.In the Production Orders, the Production Planner (after finding out from the Productionstaff) will define the raw materials, semi-finished materials required to be processed (Billsof Materials), at which location, at what time, how much work is required and the worksequence that need to be carried out (Routing). It also defines which resources are to beused and how the costs are to be settled.The Materials Requirement Planning will generate a Planned Orders from theCustomer Sales Orders or a Company-Internal Requirement (known as PlannedIndependent Requirement for Orders that are not firmed).The Planned Orders will be reviews by the Production Planner who will decide whether toconvert the Planned Orders into Production Orders and then RELEASE it for actualProduction.A firm SAP Production Order will contains information such as: What is to be produced. When the Actual Production will take place. Which Machine or Labour capacity to used to process the Order. How much will it cost to produce the Finished Goods?In the SAP system, a Production Orders can be created in the following methods: Convert from the Planned Orders generated by the SAP MRP system. Using an assembly order. Creating it manually from the SAP system.Once a Production Order is created, the system will perform the following actions: Select the Routing that contains the operations and sequences and copy it to the Production Order. The Bill of Materials is exploded and the items in the BOM are transferred to the Production Order. Reservations are created for those Bill of Materials Item held in stock. The planned costs for the Production Order are generated. The Capacity requirements are generated for the work centers define in the Routing. The Purchase Requisitions are generated for non-stock items and externally processed operations.The Master data for the Routing and BOM will only be copy once during the ProductionOrder creation UNLESS you click the Re-COPY functions (CO02 – Functions – ReadPP Master Data). Any further changes done to the Production Order for the Routing andBOM etc. will ONLY affect the Production Order and vice versa.Therefore, don’t be surprised if you found that the Original Routing and BOM structure tobe difference with the one in the Production Order as users have the right to change it, ifnecessary.@ www.sap-img.com Page 6 of 79 SAP Version 4.6c
  7. 7. A Step-by-Step Guide to the SAP PP Shop Floor Control ConfigurationsThe Bills of Materials in relation to the Shop Floor Production OrderAs you know, a bill of material is a complete structure list of the components (or rawmaterial/semi-finished) that make up a product (Finished Good).In SAP, you create the BOM level by level with Tcode “CS01”. The system can cater fordifferent type of BOM (referring to the different modules of SAP). For production you’llchoose BOM usage 1. This BOM will be copied into the Production Order whenevera new Order is created.As you can see after you enter the screen, you define the BOM level by level.@ www.sap-img.com Page 7 of 79 SAP Version 4.6c
  8. 8. A Step-by-Step Guide to the SAP PP Shop Floor Control ConfigurationsNow, let us look at a simple example:FERT requires the raw materials RAW 1 and semi-finished goods SEMI.SEMI requires the raw materials RAW 1 and RAW 2.Therefore, you’ll define two single BOM with Tcode CS01.The SAP system automatically LINK the Multi-level BOM structure for you.Now, when a user create a Production Order for FERT, two different Production Orderwill be created. One for FERT, and the other for SEMI. The reason is because FERTand SEMI requires different manufacturing process to be completed. FERT RAW 1 SEMI RAW 1 RAW 2You can used Tcode CSMB to view the Multi-level BOM. Click the button Start theMaterial BOM Browser.The system will quickly find the BOM relationship automatically for you.@ www.sap-img.com Page 8 of 79 SAP Version 4.6c
  9. 9. A Step-by-Step Guide to the SAP PP Shop Floor Control ConfigurationsStart of the SAP Production Order ConfigurationsThe SAP PP modules is closely related to the Controlling modules which takes care ofthe Costing for the Production Order. Therefore, a PP consultant will have to workclosely with the CO consultant and try your best to learn how Cost is being calculated forthe Production Order.Define the Production Order TypesInitial IMG Action : RequiredIn this configuration, you need to find out from your FICO consultant which SettlementProfile (under the Cost Controlling section) are you using although most of the time thedefault standard SAP profile PP01 is used.You have to assign every Production Order to an order type. An order type containscontrol information that you need for managing orders.Most customers will request more Production Order Types to differentiate the differentProduction Order for report analyzing purpose. For e.g.PPRW – Rework Production OrderPPPT – Trial Run Production Order etc…To create New Order Type, copy it from the Standard Order Type “PP01”.Listed below are all the transaction for each New Order Type that you need to create.All these configurations will be copied to the Production Order in transaction code “CO01”when the user create the production order. Transaction : Menu Path : OPLH IMG – Production – Shop Floor Control – Master Data – Order – Define Order Types OPL8 IMG – Production – Shop Floor Control – Master Data – Order – Define order type-dependent parameters OPJK IMG – Production – Shop Floor Control – Operations – Availability Check – Define Checking Control OPK4 IMG – Production – Shop Floor Control – Operations – Confirmations – Define Confirmations Parameters (this will determine whether confirmation is allow for this Order Type) OPU3 IMG – Production – Shop Floor Control – Operations – Scheduling – Define Scheduling Parameters for Production Orders CO82 IMG – Production – Shop Floor Control – Master Data – Order – Define number ranges for order (if different number range are required for different Order Type)@ www.sap-img.com Page 9 of 79 SAP Version 4.6c
  10. 10. A Step-by-Step Guide to the SAP PP Shop Floor Control ConfigurationsIn the Production Order type, you define the following: CO (Controlling) partner updateYou can specify whether a totals record is to be written per order if a CO partner object(for example, a cost center) is assigned to an order of this order type.This indicator is used to reduce the number of totals records and thus the storagecapacity needed in the database. Order classificationHere, you specify whether orders of this order type are to be taken into account inclassification for order summarization and the order selection. Order residence timeFind out from the user how long completed orders are left in the SAP System before theyare archived.Reorganizing an object (e.g. order, project) normally requires three steps: 1. Setting the delete flag (can be reset) 2. Setting the final deletion indicator (cannot be reset) 3. Reorganizing (writing the object to a sequential dataset and physically deleting it from the system)Residence time 1 determines the time interval (in calendar months) that must elapsebetween setting the delete flag (step 1) and setting the deletion indicator (step 2).If you leave this field blank, you can still archive the Production Order using theArchive Management transaction SARA – Object Name - PP_ORDER Settlement Profile (IMG – Controlling – Product Cost Controlling – Cost Object Controlling – Product Cost by Period – Period-End Closing – Settlement – Create Settlement Profile)Find out from the FICO consultant which settlement profile are you using to settle thisOrder Type. Collective order with goods movementThis indicator controls whether goods movements can take place for production ordersthat are linked to a collective order. Status Profile ManagementAn order can go through several processing statuses. Among other things, the statuscontrols which business transactions are allowed in the order. Number Range GeneralSAP have pre-assign the number range. If you want to change it, you can re-assign it toa new number range for each new order type. Transaction : Menu Path : IMG – Production – Shop Floor Control – Master Data – OPJH Order – Define Order TypesDouble click on the Production Order Types to reach the definition screen.@ www.sap-img.com Page 10 of 79 SAP Version 4.6c
  11. 11. A Step-by-Step Guide to the SAP PP Shop Floor Control ConfigurationsThe order category “10” which stand for production order is a fixed setting andcannot be changed. The order categories are predefined in the SAP System andcharacterize the technical properties of the orders.Click the Number range general button to assign a different number range to eachorder type. Refer to the section on Define Number Range if you need to assign aNumber Range for the Production Order Type.You’ll notice that the IMG for the Production Order type is quite straights forward.@ www.sap-img.com Page 11 of 79 SAP Version 4.6c
  12. 12. A Step-by-Step Guide to the SAP PP Shop Floor Control ConfigurationsHow to configure the Production Order User Status?A user status is activated by the user and can be created as an addition to the existingsystem status. You can define and activate any number of user statuses. To define a userstatus, you need to have created a status profile, which is created per order type inCustomizing. You can activate any number of status in a production order.The steps to configure the User Status:1. First create a Status Profile. Transaction : Menu Path : IMG – Production – Shop Floor Control – Master Data – BS02 Order – Define Status ProfileClick the Create button and type the followings:2. Type in the followings User status and Click the Object types button to assign thecorresponding to the status profile. This means that User Status 1 will be active first,then follows by the next 2 User Status.@ www.sap-img.com Page 12 of 79 SAP Version 4.6c
  13. 13. A Step-by-Step Guide to the SAP PP Shop Floor Control Configurations3. Scroll down and Tick the followings so that the status profile can be used in ProductionOrder Header as well as the Operations Level. Finished, click the Back button to gotothe Step 2 Screen.4. Assign the corresponding Business Transaction to each of the User Status exceptUser Status1 as the Initial Status was tick. Double click on User Status 2 in the screenfor Step 2.You will then see a screen with no information. Click the Create button to view the all theBusiness Transactions.@ www.sap-img.com Page 13 of 79 SAP Version 4.6c
  14. 14. A Step-by-Step Guide to the SAP PP Shop Floor Control ConfigurationsAuto move the User StatusNow, we assume that once the Order is release, it will automatically move from UserStatus 1 to User Status 2. On the Line Item Release, you click Allowed and Set button.This means that On Release of the Production Order, the status will changed to 2.Restrict the Business TransactionTo restrict any Business Transaction on a particular User Status, scroll down to theBusiness transaction line item and click Disallowed and No action. Upon User Status 3,which is the Complete Process, you can tick Disallowed for those Business transactionthat you do not want the user to do.5. Finally, assign the New Created Status Profile to the Production Order Type (OPJH).For this demo, we assign it to the Production Header.@ www.sap-img.com Page 14 of 79 SAP Version 4.6c
  15. 15. A Step-by-Step Guide to the SAP PP Shop Floor Control ConfigurationsThis is how the Production Order Screen will look like with the User Status just below theBusiness transaction status.You can click the Status button to view the Status Details.@ www.sap-img.com Page 15 of 79 SAP Version 4.6c
  16. 16. A Step-by-Step Guide to the SAP PP Shop Floor Control ConfigurationsWhere-is the Production Order Type used?Users have to choose the Production Order Type in order to create a Production Order intransaction CO01 and the configuration will be copied to the Production Order.Define the Production Order Type-dependent ParametersInitial IMG Action : RequiredFor each Production Order Type, you can define their unique IMG behavior. For eg.whether this Order Type allow automatic or manual selection of Production Version. Transaction : Menu Path : IMG – Production – Shop Floor Control – Master Data – OPL8 Order – Define order type-dependent parametersDouble click on the Production Order Types to reach the definition screen.You define the parameters that are valid for each order type and plant. The parametersare split up as follows on the tab pages:@ www.sap-img.com Page 16 of 79 SAP Version 4.6c
  17. 17. A Step-by-Step Guide to the SAP PP Shop Floor Control ConfigurationsPlanning TabstripsMaster dataFor you to define the data that influences master data selection or order master datamaintenance:Production Version You can decide whether production versions are selected automatically or manually. For manual production version, you can change the Production Versions in MRP 4 screen in MM02. Click on the ProdVersions then click the Details. For e.g. here you can set validity dates for the version or you can also set lot sizes. Based on the quantity of the order, a certain version will be picked. Or, the version will be picked if it falls in the date range.RoutingApplication The task list application is predefined as P. However, you can also specify an additional task list application.Selection ID The routing selection ID defines, for example, the ranking order for routing selection. Routing selection defines whether routings are to be selected and if so, how (manually or automatically) and whether reference operation sets can also be selected.Sequence exchange Alternative sequences and sequence exchange define whether alternative sequences are permitted and how the sequences are to be exchanged.Task list type The task list type defines which routing type is permitted for production orders.Operation dtl check Operation dtl check defines whether operation detail screens are to be checked when the operations are transferred to the order.Routing text Routing text defines that the text from the routing header is copied into the order.OperationsEntry/tool You can activate the entry tool for operations to help you when you create operations.Increment for automatic operation/activity numbering Increment used when operations or activities are automatically numbered.Reduction strategy per operation/activity Key which specifies the strategy for reducing the lead time of an operation or activity (PS). For each reduction strategy you can define up to six reduction levels.BOM application BOM application defines how the BOM alternatives are to be automatically selected. (point to the configuration OPJM – Define Applications)@ www.sap-img.com Page 17 of 79 SAP Version 4.6c
  18. 18. A Step-by-Step Guide to the SAP PP Shop Floor Control ConfigurationsBatch Determination Search procedure defines how batch determination is to take place.GeneralAssignmentSubstitute MRP ctrl Substitute MRP controller/substitute production scheduler are proposed when you create production orders if an MRP controller or production scheduler are not specified in the material master (MM01 / MM02), or if there is no reference to material.Purchase RequisitionsReservation/Purch.req. Reservation/Purch. req. specifies whether certain order objects (operation, components) are relevant to MRP.Collective purch.requisit Collective purch.req. enables collective purchase requisition per order for externally processed operations or non-stock items.Quality InspectionInspection type Inspection type defines how a quality inspection is to be carried out.@ www.sap-img.com Page 18 of 79 SAP Version 4.6c
  19. 19. A Step-by-Step Guide to the SAP PP Shop Floor Control Configurations@ www.sap-img.com Page 19 of 79 SAP Version 4.6c
  20. 20. A Step-by-Step Guide to the SAP PP Shop Floor Control ConfigurationsImplementation TabstripsStatus change documentsHere, you define whether you want change documents to be written if a status changeoccurs. You also define the level at which the change documents are to be written.A status change document contains the following: which status has been changed who changed the status whether the status has been activated or deactivated the transaction in which the status change has been carried outIn the production order , you can define the status at the following levels: order header level operation level material component level production resource/tool levelStatus change documents can also be defined independently of each other, at each ofthese four levels.Note: If you have defined these parameters such that status change documents arewritten for a particular order level, the SAP System only writes a status change documentfor a status change from this point in time if the order (or operation/component/PRT) hasbeen created since the status change documents have been activated.Please take note that SAP does not keep track of every Fields changes done to theProduction Order.Shop Floor Information System You can specify, for example, whether order data is to be stored in the Shop Floor Information System. The user can then generate reports using transaction COOIS for example, by materials, orders and work centers.Documentation of goods movements Here, you can specify that goods movements are to be documented with reference to an order. Then you can display goods movements, for example, using the order information system (Tcode COOIS). You can enter a profile for displaying documented goods movements on the tab page "Display profiles".PDC PDC active allows data to be exchanged with a PDC system.Workflow Workflow for PO chg. defines that a workflow is generated when quantities or dates that affect existing purchase orders are changed in the order. In addition, a default rule for the split is displayed on this screen. So that this indicator is also valid for production orders the appropriate settings must be made in Customizing for the Project System.Progress confirmation in orders You can determine that progress values are calculated for order progress reports.@ www.sap-img.com Page 20 of 79 SAP Version 4.6c
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  22. 22. A Step-by-Step Guide to the SAP PP Shop Floor Control ConfigurationsControlling TabstripsControllingHere, you define the parameters relevant to controlling, such as, for example, costingvariants for planned and actual costs and a results analysis key.ControllingTo set the Costing Variants (The costing variant refers to a valuation variant)IMG - Production - Shop Floor Control – Order Costing - Define Costing VariantsCosting variant for planned costs Key that specifies which costing variant is used to determine the planned costs.Use Product Cost Collector as Cost Object Specifies whether the costs are collected on a manufacturing order, (production order, process order), or product cost collector.Costing variant for actual costs Key that specifies the costing variant that is used to determine the actual costs.Results Analysis Key Key that defines the valuation of the order during period-end closing.Cost Collector - Indicator: Determine plan costs: 1/2/3 Determines whether planned costs are automatically calculated when you save the network.Net Order Price - Ind.: Copy net price from requisition into purchase order Indicator which specifies that the net price cannot be changed when copied over from the purchase requisition into the purchase order.Distribution ruleDefault rule Default (distribution) rule defines an automatically generated distribution rule for CO settlement.@ www.sap-img.com Page 22 of 79 SAP Version 4.6c
  23. 23. A Step-by-Step Guide to the SAP PP Shop Floor Control ConfigurationsDisplay profiles TabstripsCollective order display Graphics profile defines how the collective order is to be displayed.Graphic Here, you define parameters for displaying graphics of operations and sequences in the order.Missing parts list ProfMissPrtsLstOrdNo/PrfMissPrtLstCollOr defines how the missing parts list is to be displayed.Documentation of goods movements Goods movements defines which profile is used for displaying documented goods movements.@ www.sap-img.com Page 23 of 79 SAP Version 4.6c
  24. 24. A Step-by-Step Guide to the SAP PP Shop Floor Control ConfigurationsDefine Checking ControlInitial IMG Action : Usually Not requiredNormally, companies will used the same checking rule for all the Production Order Type.The following are the purpose of defining the checking rule: whether an availability check is to be carried out when you create or release an order whether an availability check is to be carried out when you save an order that has been created or released which checking rule is to be used what effect a material shortfall is to have on the creation or release of an order Transaction : Menu Path : IMG – Production – Shop Floor Control – Operations – OPJK Availability Check – Define Checking ControlHere, you define the check control. The checking rule together with the checking groupspecify the scope of the check.The checking rule as well as the actual check itself dependent on the followingparameters: • plant • order type • business functions – this control whether the check is done during production order 1 – Order Creation or 2 – Order ReleaseControl parameters for the Business functions createIn addition to this, you can specify whether a planned order can be converted to aproduction order or process order using collective conversion in the case of: • missing parts • missing PRTs or • insufficient capacityrelease control parameters for Business functionsIn addition, you can control whether an order can be released in the case of • missing materials • missing PRTs • insufficient capacity@ www.sap-img.com Page 24 of 79 SAP Version 4.6c
  25. 25. A Step-by-Step Guide to the SAP PP Shop Floor Control ConfigurationsDefine Confirmation ParametersInitial IMG Action : Usually Not requiredHere, you define the confirmation parameters for each plant and order type. This affectthe user confirmation transaction screen CO11N – Enter time ticket for production order.The parameters are split up as follows on tab pages.Generally valid settingsControl data• The properties of the control key Process control are defined elsewhere in Customizing (it can also be called using the symbol next to the control key). It controls the execution of the confirmation processes.• You can define how quantities are determined for automatically generated confirmations (milestone/progress confirmation).@ www.sap-img.com Page 25 of 79 SAP Version 4.6c
  26. 26. A Step-by-Step Guide to the SAP PP Shop Floor Control ConfigurationsChecksUsing checks you can define• what happens when the sequence of operations is not adhered to during confirmation For e,g, there are two operations 10 follows by 20, user tried to confirm operation 20 first before 10, if you configure as an Error, system will not allows it to happened. or what happens when you want to confirm a larger quantity than was confirmed for the preceding operation You can choose between a termination message, an error message, a warning message and an information message.• whether you want the total confirmed quantity of an operation checked for underdelivery or overdelivery tolerance in the order header• what effect a QM result recording has on the confirmation.• whether dates (for example, posting date, end of lead time, etc) should also be displayed with a date that is further in the future than the time of creationHR UpdateYou can decouple HR and PP with the No HR update indicator.• SelectionYou specify that only open orders are selected in the collective order.• Propose time unitsYou can select a time unit that is to be proposed during confirmation.• Goods movementsUsing the all components indicator, you can specify that the system should display allthe components assigned to the operation in the goods movement overview (in otherwords, not only backflushed components). However, if you do not branch to thematerial overview at confirmation, the system only posts backflushed components.General individual entryConfirmation function except fast entryYou can define here whether a partial confirmation, a final confirmation or a finalconfirmation with clearing of open reservations is to be proposed for the confirmation.Error handling/logsYou can use the indicator Actual costs to specify that the log is also displayed if thereare no error messages (thus only warnings or information messages). You can use theError handling indicator to specify that an error log is displayed for incorrect items ingoods movements (for backflush or automatic goods receipts). You then have anotheropportunity to correct the items with errors before saving, with the aid of the materialoverview.Operation indiv. entry using initial scrn TabsrtipsPropose data to be confirmedYou can have the system propose the open confirmation data for entry. For the quantitiesand activities, the SAP System proposes the difference between the standard values andthe confirmed values. Otherwise, the standard values are proposed as confirmation data.Display confirmed data/display standard valuesYou can have the system display both the confirmed data and the standard values forinformation purposes.Screen control time ticket@ www.sap-img.com Page 26 of 79 SAP Version 4.6c
  27. 27. A Step-by-Step Guide to the SAP PP Shop Floor Control ConfigurationsIf you do not select an entry screen on the initial screen, you can control the followingalternative entry screens by parameterization:• Screen with the most important actual data without a display of the values already confirmed and the standard values• Screen with quantities and activities and a display of the values already confirmed and the standard values• Screen with quantities and activities, forecasted standard values and a display of the values already confirmed and the standard valuesYou define that confirmable or confirmed operations are also selected during theexecution of the confirmation processes Transaction : Menu Path : IMG – Production – Shop Floor Control – Operations – OPK4 Confirmation – Define Confirmation ParametersDefine the parameter settings for the confirmations in your plant for the possible ordertypes. Double click on the line items to configure the detail settings.@ www.sap-img.com Page 27 of 79 SAP Version 4.6c
  28. 28. A Step-by-Step Guide to the SAP PP Shop Floor Control ConfigurationsGenerally valid settings Tabstrips@ www.sap-img.com Page 28 of 79 SAP Version 4.6c
  29. 29. A Step-by-Step Guide to the SAP PP Shop Floor Control ConfigurationsGeneral individual entry TabstripsOperation indiv. entry using initial scrn Tabsrtips@ www.sap-img.com Page 29 of 79 SAP Version 4.6c
  30. 30. A Step-by-Step Guide to the SAP PP Shop Floor Control ConfigurationsDefine Scheduling Parameters for Production OrdersInitial IMG Action : Usually Not requiredHere, you define for each plant, order type and production scheduler the parameters forscheduling production orders. This comprises maintaining • scheduling levels (detailed, production-rate and rough-cut scheduling) • date adjustment when dates are exceeded • date control for detailed scheduling • reductionThe parameters are described in what follows in details:In detailed-, rate-based and rough-cut scheduling you define for every schedulinglevel • how production dates are to be calculated • whether capacity requirements are generated • which routing is the basis for schedulingIf a production version exists in the material master then the routing is selected using thisversion. If no version exists for a scheduling level then a routing is selected according tothe selection ID that you have given for the scheduling level. In Adjust dates you specify whether and how the basic dates are adjusted to the production dates (for example, when deadlines are exceeded) and how dates for dependent requirements are to lie. In Scheduling control for detailed scheduling you specify the control parameters for detailed scheduling, among other things the scheduling type (most manufacturing companies will used the Backwards Scheduling where the system will calculate bottom up from the lowest BOM level to determine the Basic Start date required by the Production Order for producing the Finished Product). Start date in the past Here you specify how many days an order may lie in the past before today scheduling is triggered. Automatic scheduling Here you specify whether scheduling is carried out automatically on saving. Automatic log Here you specify whether the log is displayed automatically on scheduling. Latest date f. materialHere you specify where the required date of a component should be with respect to anoperation. Scheduling with break Here you specify that the exact time a break occurs must be taken into account. From production dates Here you specify that when you create or change an order the user must enter schedules dates (production dates) instead of basic dates. Shift order Here you specify whether the order can be moved if partially confirmed operations exist. Reduction type@ www.sap-img.com Page 30 of 79 SAP Version 4.6c
  31. 31. A Step-by-Step Guide to the SAP PP Shop Floor Control Configurations• whether in the order or in the collective order all the operations are to be reduced or only those along the critical path.• Reduction along the critical path is only possible for networks, production orders and planned orders with parallel sequences and for collective orders that contain production orders or planned orders. Maximum Reduction level up to which maximum reduction level the reduction takes place % reduction in floats to what percentage the float before and after production in every reduction level is to be reduced.Note that scheduling is always carried out for all scheduling levels that you havespecified. For example, if you make changes in the order that are relevant to scheduling(basic dates, quantities) and schedule it again then scheduling is carried out not only fordetailed planning but also for production-rate and rough-cut planning.This is very performance-intensive because data must be read from the database.Therefore it is recommended that you only maintain levels relevant to scheduling.Whereas you can choose between several scheduling types for detailed scheduling,rough-cut and production-rate scheduling always use backward scheduling. Reductionsare also only relevant for detailed scheduling. Transaction : Menu Path : IMG – Production – Shop Floor Control – Operations – OPU3 Scheduling – Define Scheduling Parameters for Production OrdersDefine the scheduling parameters for production orders. When finished, you can test thescheduling parameters by creating a Production Order with transactions “CO01”.@ www.sap-img.com Page 31 of 79 SAP Version 4.6c
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  33. 33. A Step-by-Step Guide to the SAP PP Shop Floor Control ConfigurationsDefine Number RangeInitial IMG Action : RequiredNumber ranges for OrdersThe Number ranges for orders are preset in the SAP default settings.Some companies may request to have different number range for different Order Types.This is an example on how to define the number ranges for order: Transaction : Menu Path : IMG – Production – Shop Floor Control – Master Data – CO82 Order – Define number ranges for orderClick the Intervals button to configure the number ranges.Click the Groups button to assign the Production type to the number rangesIf you have a new Production Type, scroll down to view those Production Type notassigned.To assign the Production type, park your cursor at the Production Type and click the (Select Element) button.Finally, tick the box of the main group and click the (Assign ElementGroup) button to assign the Production Order Type.@ www.sap-img.com Page 33 of 79 SAP Version 4.6c
  34. 34. A Step-by-Step Guide to the SAP PP Shop Floor Control ConfigurationsTo Change the Group text, tick the group box and click the Menu Group -> Maintain textIn the standard SAP R/3 System, number ranges for the followings are preset. Transaction : Menu Path : CO80 IMG – Production – Shop Floor Control – Master Data – Order – Define number ranges for confirmations CO83 IMG – Production – Shop Floor Control – Master Data – Order – Define number ranges for reservations CO81 IMG – Production – Shop Floor Control – Master Data – Order – Define number ranges for operations CO84 IMG – Production – Shop Floor Control – Master Data – Order – Define number ranges for capacity requirements@ www.sap-img.com Page 34 of 79 SAP Version 4.6c
  35. 35. A Step-by-Step Guide to the SAP PP Shop Floor Control ConfigurationsDefine selection profiles for the Order Information SystemInitial IMG Action : Not requiredHere, you define the selection profiles that you can use to specify status combinations forselecting objects (for example, orders or operations). A selection profile is especiallyuseful if you select a large number of objects repeatedly according to the same selectionconditions (for example, orders for printing shop papers, for collective release, or forcreating order valuations). Transaction : Menu Path : IMG – Production – Shop Floor Control – Master Data – BS42 Order – Define selection profilesTo view the Selection conditions screen, select the SelProf you want and click SelectionconditionsThis is the Selection conditions screen where you configure the pre-define Status.@ www.sap-img.com Page 35 of 79 SAP Version 4.6c
  36. 36. A Step-by-Step Guide to the SAP PP Shop Floor Control ConfigurationsWhere-is the Selection Profile used? Transaction : SAP Menu Path : Logistics – Production – Production Control – COOIS Information System – Order Information SystemLook at the field name “Selection profile status”.@ www.sap-img.com Page 36 of 79 SAP Version 4.6c
  37. 37. A Step-by-Step Guide to the SAP PP Shop Floor Control ConfigurationsDefine the Production Operations Control keyInitial IMG Action : Usually Not requiredUsing the control key of the operation you determine • which business functions you want to carry out • how an operation should be dealt withThe most important functions are: SchedulingWith this indicator you control whether the operation is scheduled Det. Capacity planningWith this indicator you control whether capacity requirements records are written for theoperation Inspection characteristics requiredWith this indicator you control whether inspection characteristics have to be maintainedfor the operation Automatic goods receiptWith this indicator you determine that the yield quantity is posted to the warehouseautomatically when the operation is confirmed Printing time ticketsYou can use indicators to control whether time tickets or completion confirmation slips(referring to shop floor paper) should be printed for an operation CostWith this indicator you control whether the operation is to be taken into account in costing. Sched. external op / External ProcessingWith this indicator you control whether the operation is to be processed externally. ConfirmationsWith this indicator you control • whether the confirmation of an operation is allowed, possible or required • whether the operation is to be marked as a partial completion confirmation Transaction : Menu Path : IMG – Production – Shop Floor Control – Master Data – OPJ8 Routing Data – Define control keyDouble click on the Control key to configure the settings.@ www.sap-img.com Page 37 of 79 SAP Version 4.6c
  38. 38. A Step-by-Step Guide to the SAP PP Shop Floor Control ConfigurationsWhere-is the Control key used?Transaction : SAP Menu Path : Logistics – Production – Master Data – Work CenterCR03 – Work Center – Display - DefaultsThe Control key will be automatically copy when user create the Routing. TheRouting will be copy when user create the Production Order.@ www.sap-img.com Page 38 of 79 SAP Version 4.6c
  39. 39. A Step-by-Step Guide to the SAP PP Shop Floor Control ConfigurationsDefine formula parameters for Work CenterInitial IMG Action : RequiredIn the PRT management you need formula parameters to define: • formulas that are used to calculate the required total quantity and the total usage value of a production resource/tool • formula constants in PRT master records of the category "Other"You also need formula parameters for work center maintenance to • describe standard values • define formulasThese formulas are used to calculate the capacity requirements, the lead times and thecosts in capacity planning, scheduling and (general). Transaction : Menu Path : IMG – Production – Shop Floor Control – Master Data – OPKL Production Resources/Tools – Formulas – Define Formula parametersClick the New entries button to create a new Formula Parameters.@ www.sap-img.com Page 39 of 79 SAP Version 4.6c
  40. 40. A Step-by-Step Guide to the SAP PP Shop Floor Control ConfigurationsTransaction : Menu Path : IMG – Production – Shop Floor Control – Master Data –OPKM Production Resources/Tools – Formulas – Define Formula@ www.sap-img.com Page 40 of 79 SAP Version 4.6c
  41. 41. A Step-by-Step Guide to the SAP PP Shop Floor Control ConfigurationsType in the Formula that you want. Refer to the Formula Parameters (Tcode OPKL)for the Fields Name.@ www.sap-img.com Page 41 of 79 SAP Version 4.6c
  42. 42. A Step-by-Step Guide to the SAP PP Shop Floor Control ConfigurationsWhere-is the Work Center Formula Used? Transaction : SAP Menu Path : Logistics – Production – Master Data – Work Center CR02 – Work Center – Change - CostingTo check the Formula, park your cursor at the Activity type and click Extras – FormulaDisplay.The Work Center formula will be copied to the Production Order during order creation(CO01).Define the Production Scheduling ProfileInitial IMG Action : Usually Not requiredHere, you can create the production scheduling profiles for specific plants.In a production scheduling profile, you can • specify that in a production order or process order particular business transactions are carried out in parallel • order auto release on order creation • generation of document link from material master on order creation • generation of document link from BOM on order creation • auto printing of shop floor papers on order release • scheduling on order release@ www.sap-img.com Page 42 of 79 SAP Version 4.6c
  43. 43. A Step-by-Step Guide to the SAP PP Shop Floor Control Configurations • generation of document link from material master on order release • generation of document link from BOM on order release • specify that only partial quantities are to be confirmed in an availability check • specify that automatic goods receipt should take place • enter an overall profile for capacity leveling • specify how the capacity requirements of operations should go into the basic load • specify when finite scheduling is carried out in the capacity availability check • specify that for the confirmation • no deficit quantities are updated • no surplus quantities are updated • neither deficit nor surplus quantities are updated • an adjustment of the operation and component quantities to the actual values takes place • make various specifications in the area of batch management: • automatic batch creation on order creation • branch to batch classification on changing a batch • extended batch classification via Customer Function Call • specify that only transport requirements are created if transport requirements can be generated for all components in the operation • specify that when transport requirements are generated either the committed quantity or the required quantity are taken into account • specify that the creation of transport requirements takes place automatically • specify which order type is proposed depending on the business process (make- to-stock, make-to-order, engineer-to-order, order without material)You can assign a production scheduling profile to a • material (work scheduling view in material master – Tcode MM01/MM02) • production scheduler (Customizing – Tcode OPJ9)The assignment to the material has a higher priority.The production scheduling profile is copied to the production order or processorder on order creation. Transaction : Menu Path : IMG – Production – Shop Floor Control – Master Data – OPKP Trigger Point – Define production scheduling profileDouble click the Plant to configure the detail settings.@ www.sap-img.com Page 43 of 79 SAP Version 4.6c
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  45. 45. A Step-by-Step Guide to the SAP PP Shop Floor Control ConfigurationsDefine Production SchedulerInitial IMG Action : RequiredIn this step, you define the production schedulers for your plants. In addition to this, youcan assign a control profile to each production scheduler.By assigning production schedulers to materials within the application, you can defineresponsibilities for a materials within production activity control. Transaction : Menu Path : IMG – Production – Shop Floor Control – Master Data – OPJ9 Trigger Point – Define production schedulerWhere-is the Production Scheduling Profile and Production SchedulerUsed?Create (MM01) or Change (MM02) Material Master (Work scheduling View)@ www.sap-img.com Page 45 of 79 SAP Version 4.6c
  46. 46. A Step-by-Step Guide to the SAP PP Shop Floor Control ConfigurationsDefine User Exits SelectionInitial IMG Action : Not requiredMost companies will choose not to implement any additional ABAP routines for selectinga routing or alternative routing unless really necessary.In this menu option, you can permit the user to select task lists.You can define separate ABAP/4 routines for each of the following parameters: • Task list application • Task list type • Selection IDThese parameters are then automatically used to select a routing or a routing alternative. Menu Path : IMG – Production – Shop Floor Control – Operations – Task List Selection – Define User SelectionDouble click on the Application to configure the user-exits.@ www.sap-img.com Page 46 of 79 SAP Version 4.6c
  47. 47. A Step-by-Step Guide to the SAP PP Shop Floor Control ConfigurationsSelect Routing AutomaticallyInitial IMG Action : Usually Not requiredIn this menu option, you determine the selection criteria for the automatic plannedselection of alternatives using the selection ID.You can define several selection priorities for every selection ID. You allocate theselection criteria to these priorities in each case.An alternative routing is searched for during the automatic planned selection ofalternatives that corresponds to the selection criteria.Selection criteria are, for example: • Routing type • Task list usage • Routing statusIf no alternative routing can be calculated, the SAP System continues searching with theselection criteria of the next lowest selection priority.The selection ID is determined by the order type within the production activitycontrol.Define the following for every selection ID: • Selection priority • Routing type • Task list usage • Routing status Transaction : Menu Path : IMG – Production – Shop Floor Control – Operations – OPJF Task List Selection – Select Automatically@ www.sap-img.com Page 47 of 79 SAP Version 4.6c
  48. 48. A Step-by-Step Guide to the SAP PP Shop Floor Control ConfigurationsWhere do you define the Usage and Status?You define Usage and Status when you create the Routing in transaction “CA01”. TheTask List Type will be default as “N”.Define Default Values If No Routing ExistsInitial IMG Action : Usually Not requiredIn certain company, routing might not required as BOM is only required for the ProductionOrder. For this kind of requirement, you will configure this settings in which you specifywhich data is contained in an operation that is automatically created during ordercreation.Within order creation, you can determine that an operation is created automatically if norouting exists for the material to be produced or no routing can be selected.The automatically created operation should contain the following data, for example: • control keyThe control key specifies how an operation is processed (for example, whether it isscheduled, costed, etc.) • operation number • operation short text • material group (only for external processing) • work center where the operation is carried out@ www.sap-img.com Page 48 of 79 SAP Version 4.6c
  49. 49. A Step-by-Step Guide to the SAP PP Shop Floor Control Configurations Transaction : Menu Path : IMG – Production – Shop Floor Control – Operations – OPJG Task List Selection – Define Default ValuesSpecify the data for operations automatically created by the system.@ www.sap-img.com Page 49 of 79 SAP Version 4.6c
  50. 50. A Step-by-Step Guide to the SAP PP Shop Floor Control ConfigurationsDefine Priorities for BOM UsagesInitial IMG Action : Usually Not requiredHere, you can specify different sequences of priorities of BOM usages.Every process relating to automatic alternative determination is represented via anapplication. Among other things, a selection ID is calculated via this application. Theselection ID conceals a certain sequence of priorities of BOM usages.When specifying the selection ID, you must know the required applications.If you use only one BOM usage, you must define a selection ID with priority 1. Transaction : Menu Path : IMG – Production – Shop Floor Control – Operations – Bill OPJI of Material Selection – Define Priorities for BOM UsagesSpecify different sequences of priorities of BOM usages according to your requirements.Define Applications for BOM ExplodeInitial IMG Action : Usually Not requiredHere, you define the processes relating to automatic alternative determination.Every process is represented via an application. You need this application in order toexplode a BOM during order creation.The alternative determination is controlled both by the application and the settings in thematerial master.In the material master, you can specify in the field "Alternative selection" whether youwant an alternative to be selected according to one of the following parameters: • order quantity • date • production versionVia the application, you specify the following criteria: • priority sequence for BOM usage (selection ID)@ www.sap-img.com Page 50 of 79 SAP Version 4.6c
  51. 51. A Step-by-Step Guide to the SAP PP Shop Floor Control Configurations • priority of a certain alternative for a special multiple BOM dependent on dateYou can specify per application whether the settings should be taken into account for thealternative selection for multiple BOMs. These settings are only taken into account if youselected the alternative selection according to date in the corresponding material master. • take production version into accountIf you selected the alternative selection according to production version in the materialmaster, you can specify here for every application whether this setting should be takeninto account. If this setting is not to be taken into account, the alternative selection iscarried out for the corresponding material and application according to order quantity. • Indicator of the BOM statusDuring alternative determination, only those bills of material are taken into account whosestatus at least contains the indicators specified here.During order creation, the application is determined on the basis of order type.RequirementsYou must have processed the menu option "Alternative selection for multiple BOMs"(Transaction OS32).Define the applications according to your requirements. Double click on theApplications to configure the detail settings.@ www.sap-img.com Page 51 of 79 SAP Version 4.6c
  52. 52. A Step-by-Step Guide to the SAP PP Shop Floor Control ConfigurationsDefine Alternative Determination for ProductionInitial IMG Action : Usually Not requiredIn this menu option, you define how automatic alternative determination is to run from thepoint of view of production.First process menu option "Define applications" (Transaction OPJM). Menu Path : IMG – Production – Shop Floor Control – Operations – Bill of Material Selection – Define Alternative Determination for ProductionEnter an application depending on plant and order type.@ www.sap-img.com Page 52 of 79 SAP Version 4.6c
  53. 53. A Step-by-Step Guide to the SAP PP Shop Floor Control ConfigurationsDefine Checking GroupInitial IMG Action : Usually Not requiredHere, you define the checking groups. You must allocate each material you want tochecked for availability to a checking group. You can allocate the material in thematerial master.The checking group groups together materials checked according to the same criteria.Materials can be grouped according to material type and/or MRP type, for example.You can also use the checking group to control whether • the quantities confirmed in the availability check are to be locked • during the check the normal ATP quantity or the cumulated ATP quantity is to be used.You allocate the checking group to the material in the material master under theavailability check field in the MRP data screen.If you have not maintained a checking group for a material, the material will not bechecked for availability. Transaction : Menu Path : IMG – Production – Shop Floor Control – Operations – OVZ2 Availability Check – Define Checking GroupDefine the necessary checking rules.@ www.sap-img.com Page 53 of 79 SAP Version 4.6c
  54. 54. A Step-by-Step Guide to the SAP PP Shop Floor Control ConfigurationsDefine Checking RuleInitial IMG Action : Usually Not requiredHere, you can define checking rules for the following applications: Sales and distribution MRP Production order processing Maintenance order processing Inventory managementYou can thus carry out various application-related checks for a material. Menu Path : IMG – Production – Shop Floor Control – Operations – Availability Check – Define Checking RuleFor the company, define whether there is a need to check on a differentiated basis foreach application.Define Scope of CheckInitial IMG Action : Usually Not requiredHere, you define the check scope. Checking group and checking rule together specify thescope of the check.You can specify the following: • which elements relevant to MRP (inward goods movements/outward goods movements) are taken into account (for example, purchase requisition, purchase order, planned order) • which stock categories are taken into account • whether replenishment lead time is checkedSpecify • which inward goods movements and which outward goods movements are to be included in the availability check • which stocks are to be included in the availability check • whether the check should take into account the replenishment lead time • whether the availability should always be checked at plant level.@ www.sap-img.com Page 54 of 79 SAP Version 4.6c
  55. 55. A Step-by-Step Guide to the SAP PP Shop Floor Control Configurations Transaction : Menu Path : IMG – Production – Shop Floor Control – Operations – OPJJ Availability Check – Define Scope of CheckDouble click the Checking rule to configure the detail settings.@ www.sap-img.com Page 55 of 79 SAP Version 4.6c
  56. 56. A Step-by-Step Guide to the SAP PP Shop Floor Control ConfigurationsDefine Checking Rule for Backorder ProcessingInitial IMG Action : Usually Not requiredHere, you can determine a checking rule per plant for backorder handling. The checkingrule determines the scope of check for backorder handling.It is recommended that you use the same checking rule for backorder handling as you dofor availability checks.Menu Path : IMG – Production – Shop Floor Control – Operations – Availability Check –Define Checking Rule for Backorder ProcessingDefine the necessary checking rules.@ www.sap-img.com Page 56 of 79 SAP Version 4.6c
  57. 57. A Step-by-Step Guide to the SAP PP Shop Floor Control ConfigurationsSpecify Scheduling TypeInitial IMG Action : Not requiredHere, you define the scheduling type, which determines how the SAP System shouldcarry out scheduling. There are the following options: Forwards Backwards No scheduling "Today" scheduling Basic dates with times (only for process orders)You can save the scheduling type in the control data for scheduling depending on theorder type. It is then proposed by the SAP system when an order is created.Scheduling types are predefined in the SAP standard package. It is recommended thatyou work with these predefined scheduling types. Transaction : Menu Path : IMG – Production – Shop Floor Control – Operations – OPJN Scheduling – Specify Scheduling Type@ www.sap-img.com Page 57 of 79 SAP Version 4.6c
  58. 58. A Step-by-Step Guide to the SAP PP Shop Floor Control ConfigurationsDefine Standard Value KeysInitial IMG Action : RequiredHere, you can maintain the standard value keys. The standard value key determines themeaning of the standard values. It is used to assign parameter IDs to the six standardvalues of operations and the work in network activities.These parameter keys determine the following: • the key word displayed for the standard value on the screen, for example, setup, machine, labor, tear down • the dimension (for example, time, quantity, volume) of the standard valueAt the same time, the parameter IDs are the names used for the standard values for thecalculation of: • execution time • capacity requirements • costsA parameter which is to be used in a standard value key must have the origin "2". Transaction : Menu Path : IMG – Production – Shop Floor Control – Operations – OPJQ Scheduling – Define Standard Values Keys1. Define the parameter IDs for the standard standard values.2. Define the standard value key.Double click on Standard values to configure the detail settings.@ www.sap-img.com Page 58 of 79 SAP Version 4.6c
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  60. 60. A Step-by-Step Guide to the SAP PP Shop Floor Control ConfigurationsWhere-is the Standard Value Key used?The user define the Standard Value Key when they create the Work Center – tabstripsBasic data (transaction CR01).Define Scheduling Margin KeyInitial IMG Action : Not requiredThe system will calculate a longer Start and Finish period when the user create theProduction Order if addition buffer days are configured.In this menu option, you specify time floats for scheduling as well as the release periodfor order release.The following floats are defined: float before productionThis is the time between the order start date and the scheduled start date. float after productionThis is the time between the order finish date and the scheduled finish date.@ www.sap-img.com Page 60 of 79 SAP Version 4.6c
  61. 61. A Step-by-Step Guide to the SAP PP Shop Floor Control ConfigurationsThe release date is calculated by adding the release period. The order release is carriedout on this date.Via the release period key you can specify the following for each material: • float before production • float after production • release periodThe following parameters are always defined in days: • float before production • float after production • release period Menu Path : IMG – Production – Shop Floor Control – Operations – Scheduling – Define Scheduling Margin KeyDefine the release period key for the material.Define Capacity CategoriesInitial IMG Action : RequiredYou can assign several capacities of different capacity categories to a work center.Capacity categories can be, for example: • Machine • Personnel • Setup personnel • EmissionsYou have to define the availability for every capacity of the work center (for example,work start, work finish, calendar, etc.). You can create these values as default values foreach plant and capacity category.@ www.sap-img.com Page 61 of 79 SAP Version 4.6c
  62. 62. A Step-by-Step Guide to the SAP PP Shop Floor Control Configurations Menu Path : IMG – Production – Shop Floor Control – Operations – Capacity Requirements Planning – Define Capacity Categories1. Define the possible capacity categories.2. Define the default values for the capacity categories.Where-is Capacity Categories used?The user assigned the Capacity category when they create the Work Center –tabstrips Capacities (transaction CR01).@ www.sap-img.com Page 62 of 79 SAP Version 4.6c
  63. 63. A Step-by-Step Guide to the SAP PP Shop Floor Control ConfigurationsDefine Single Screen Entry for Time Ticket ConfirmationsInitial IMG Action : Usually Not requiredIn this step you define the confirmation profile for single screen entry of time ticketconfirmations and also for reprocessing time ticket confirmations containing errors.You can define the layout of the entry screen. When you do this, you define which inputand output fields are displayed and in which order. These definitions are saved inprofiles. A profile is assigned to an individual user in the user parameter CORUPROF(transaction SU01 – Click Changed button – Parameters tabstrips – Enter ParametersCORUPROF and Value Profile Name.ReprocessingThe reprocessing indicator defines whether the profile is to be used for single screenentry or for the reprocessing of time ticket confirmations with errors. Under one profilename, you can have a definition for each application situation.Standard profileWith the Standard prof. indicator, you can define that the profile is to be used as thestandard profile. Only one profile each can be defined as the standard profile for singlescreen entry and reprocessing of time ticket confirmations with errors. The standardprofile is then used if no profile has been assigned to the user in the user parameterCORUPROF or if the profile that has been assigned does not exist.Area selectionIn the header area you can define which data is to identify the operation to be confirmed.Here, for example, you can define whether only the confirmation number and/or order,sequence, operation can be entered.In the detail areas, you define which information can be entered for the operation to beconfirmed and in which order the fields in question are displayed. You can select up toseven detail areas, each containing one group of possible entry fields. Note that everyinput and output field can only be issued once. When you save, the system automaticallychecks whether this rule has been adhered to. To carry out this check beforehand,choose the pushbutton Check area selection.Titles can be assigned to the detail areas, which are reproduced on the pushbuttonsabove the corresponding area. You can use these pushbuttons to open and close theareas. This means that the number of fields on the screen can be kept to a minimum.With the "Closed" indicator you define that the area is to be closed when the function isfirst called up.You can display a preview of the individual area and also of the entire entry screen. To dothis, choose the corresponding pushbutton (Header area preview, Detail area preview,List screen preview )Defaults • Confirmation function@ www.sap-img.com Page 63 of 79 SAP Version 4.6c
  64. 64. A Step-by-Step Guide to the SAP PP Shop Floor Control ConfigurationsYou define whether a partial confirmation, final confirmation or a final confirmation withposting of open reservations is to be proposed. • Default valueYou can define the time of default determination for quantities and/or activities: • no proposal • immediate proposal • proposal when savingFor default determination • the quantity that is still to be confirmed is calculated • the activities are calculated in proportion to the quantities • Activities/forecastFor both the activities and forecast values, you can define 6 texts that are displayedduring confirmation entry. These texts are overwritten with the texts from the standardvalue key in the work center after you have chosen ENTER. If you want to prevent thisfrom happening, set the indicator "Fix text". You can hide activities or forecast values forwhich you do not want to enter a confirmation by setting the indicator "Hidden".Maintain language-dependent textsThe texts entered for the pushbuttons in the detail areas, as well as for the activities andforecast values, are saved in the logon language. If you want to process the texts inseveral languages, use the IMG activity "Maintain Language-Dependent Texts".Profile assignmentThe confirmation profile assigned to a user depends on the application and theCORUPROF parameter entry in the user parameters: • Single screen entryA profile is used that agress with the CORUPROF parameter entry and in which thePostprocessing indicator has not been set. • PostprocessingA profile is used that agress with the CORUPROF parameter entry and in which thePostprocessing indicator has been set.If the user has not been assigned a confirmation profile in the CORUPROF userparameter or the assigned profile does not exist, then the standard profile for theapplication is used. If there is not a standard profile, a firmly defined user interface ispresented. Transaction : Menu Path : IMG – Production – Shop Floor Control – Operations – OPK0 Confirmation – Single Screen Entry – Define Single Screen Entry1. Define the confirmation profile.2. Display the preview of each profile and check the profiles.3. Enter the texts for the profile in other languages, if necessary (IMG activity Maintain Language-Dependent Texts).4. In the user parameter CORUPROF, assign confirmation profiles to the individual users.For the detail areas, there are also 3 screens available whose layout you can defineyourself. The definitions required for this are made via the user exit CONFPP07.@ www.sap-img.com Page 64 of 79 SAP Version 4.6c
  65. 65. A Step-by-Step Guide to the SAP PP Shop Floor Control ConfigurationsDouble click on the Confirm profile to change the screen setting for “CO11N”.Tick the Standard Profile if you want the settings to be default whenever CO11N is used.After the changes, click the Preview button to check the screen layout.Area selection Tabstrips@ www.sap-img.com Page 65 of 79 SAP Version 4.6c
  66. 66. A Step-by-Step Guide to the SAP PP Shop Floor Control ConfigurationsDefault TabstripsMaintain Language-Dependent TextsInitial IMG Action : Not requiredThis configuration are for those with a multiple language environment.In this step, you can maintain the texts in the profile for single screen entry ofconfirmations in several languages: • Push button text in the header area • Push button texts in the detail areas • Activity texts • Forecast texts Transaction : Menu Path : IMG – Production – Shop Floor Control – Operations – OPK0T Confirmation – Single Screen Entry – Maintain Language-Dependent TextsMaintain the confirmation profile texts in the languages required.@ www.sap-img.com Page 66 of 79 SAP Version 4.6c
  67. 67. A Step-by-Step Guide to the SAP PP Shop Floor Control ConfigurationsDefine Reasons for Variances for Production ScrapInitial IMG Action : RequiredIn this menu option, you define the causes of variances. You thus define the reasons thatcan be given if a variance occurs, in order to document this variance.Variances might be: • scrap on a quantity basis • excess consumption of activities • longerexecution time • other resource, etc. Transaction : Menu Path : IMG – Production – Shop Floor Control – Operations – OPK5 Confirmation – Single Screen Entry – Define Reasons for VariancesDefine the possible causes of variances that could occur in your company.@ www.sap-img.com Page 67 of 79 SAP Version 4.6c
  68. 68. A Step-by-Step Guide to the SAP PP Shop Floor Control ConfigurationsWhere-is the Production Reason Code used?The Reason Code is used when the user enter a Scrap quantity during the ProductionOrder confirmations. Every Scrap quantity must have a reason attached to it.Define Print Control for Shop Floor PapersInitial IMG Action : RequiredIn this step you make the settings necessary for printing shop floor papers (transactionCO04N) or directly from the production order (menu – Functions – Print).If you do not want to use the standard shop floor papers then you first have to design anew layout set (ABAP effort will be required).Use a standard layout set as a reference (for example PSFC_STD_LAYOUT) to write anew print report.Use as a reference a print program that belongs to the standard layout set (for example,PSFCCONF) Transaction : Menu Path : IMG – Production – Shop Floor Control – Operations – OPK8 Confirmation – Define Print Control@ www.sap-img.com Page 68 of 79 SAP Version 4.6c
  69. 69. A Step-by-Step Guide to the SAP PP Shop Floor Control ConfigurationsTo define the print control, proceed as follows: 1. Maintain the list names. 2. Define the spool parameters for the user. 3. Maintain the reference order types. 4. Maintain the layout sets and maintain the relevant parameters for them. 5. Maintain the print programs for each list. 6. Specify the transactions from which you can print and maintain the relevant parameters for them. (list control for transactions). 7. Maintain the printer specification. 8. Specify the spool parameters for the print procedure. 9. If necessary define the table accesses for the individual fields in the lists.Click Spool parameters for user to reach this screenDouble click on the User Name to the Print List and Printer Name for each user.The control are Plant and User Login name.Listed in the Spool parameters for user are all the user names that are allowed to printthe shop papers.Double click on the user name that are allowed to print the shop papers.Here you tick on the Print column the Print Shop Paper Layout that will be used. Youcan specify the default printer if you want. To print immediately, just tick the Immed.column.@ www.sap-img.com Page 69 of 79 SAP Version 4.6c
  70. 70. A Step-by-Step Guide to the SAP PP Shop Floor Control ConfigurationsClick Reference order types to configure the RefOrdType for the Production Order.Click Forms to configure any new SAPscripts that you may have.Click on Print programs to configure any new Report name you may have.Click on Printer Specification and configure how you want to control the Output device.@ www.sap-img.com Page 70 of 79 SAP Version 4.6c
  71. 71. A Step-by-Step Guide to the SAP PP Shop Floor Control ConfigurationsClick on Flow control for transactions to configure how you want to process theprinting.@ www.sap-img.com Page 71 of 79 SAP Version 4.6c
  72. 72. A Step-by-Step Guide to the SAP PP Shop Floor Control ConfigurationsPreparing the Initial Implementation of the PP Shop Floor Control ModuleBefore the live-implementation of the SAP system, there will be a cut-off day to turn-onfrom the OLD to the NEW SAP system. The PP Shop Floor Control module is one of themost important module although it belongs to the last process flow because theProduction Floor will based on the Production Order Generated to produce the FinishedGoods for the Customer.As a PP consultant, you have to inform the users that they have to get those CRITICALdata into the system before going live. Work Center Master Bills of Materials Master Routing MasterRemember that when the user create a new Production Order, the system will READfrom the BOM and Routing Master.Take note that the Master data can be input into the SAP system even BEFORE goinglive as long as there are no transaction postings such as Production Confirmation whichwill impact the Financial figures.Normally, in an on-going business, there will be existing OPEN non-SAP ProductionOrder. You must let the EVERYONE know that as the days come nearer to theimplementation date, they must try to keep the OPEN non-SAP Production Order quantityjust enough to be CLOSE before going live. For e.g. if the ACTUAL production quantityis 10,000 and they estimate that they can only complete 3,000 by the time of theImplementation, they should only CREATE the production order to produce 3,000 only.The other 7,000 should only be created AFTER going live on the NEW SAP system.How about those Process Incomplete Production Order?In a manufacturing environment, Division of Labor means Jobs are separated in stagesas to achieve maximum Productivity. There are certain cases of Incomplete ProductionProcess where 3,000 was completed in Process 1. When it reaches Process 2, only1,000 can be completed. In this case, the user still have to close the non-SAP ProductionOrder and RE-OPEN a new SAP Production Order for the remaining 2,000 for Process 2.They have to take note of the difference either on the non-SAP Production Order or as aText note on the SAP Production Order.Production Floor users are also recommended to return all those additional raw materialsto the Inventory Stores. This will aid in the accuracy of the Physical Stock count. Theycan then re-draw the raw materials after going-live.@ www.sap-img.com Page 72 of 79 SAP Version 4.6c
  73. 73. A Step-by-Step Guide to the SAP PP Shop Floor Control ConfigurationsStatic versus dynamic data conversionIn general, data could be classified as begin either static or dynamic data.Static data includes items that are relatively stable such as vendor master, materialmaster, BOM, routing, work centers, customer master, price agreement, material group,activity prices, cost centers etc.Dynamic data includes items such as inventory balances, A/R balances, A/P balances,GL balances, Open Production Orders, Open Sales Orders, Open Purchase Orders andPlanned Independent Requirements.In general, we will have lots of time to convert the static data but insufficient time to rushthe dynamic data into the system. This is because dynamic data must be converted witha clear cut-off date. This means that the balances must be that of the same point intime in order to ensure the integrity of data.Where the volume of data in relation to the number of end users is high, we will considerautomating the conversion, provided that data is available from the old system.If the volume is low or if data is not available from the present system, users should keythe data directly into SAP. This approach has an added and important benefit oftraining the end users in the operation of the SAP system.A Sample Note to users regarding the Uncompleted Production OrdersThis is the most complex area for conversion. We must take the following step tominimize the number of uncompleted production orders. Three weeks before the cut-over date, all un-started and newly created production orders will be marked with a special color code. A bold instruction “Do not record component issue and labor cost until completion” will be stamped on these production orders. We will withhold the recording of material issues and production activities in the Old System and related systems if the production orders are color coded. If the production orders are completed and need to be received into stores before the cut-over date, we will then enter the component issue and labor activity to the production orders before the goods receipts of the finished product. If the production orders are not completed before the cut-over date, we will manually create the production orders in SAP and enter the confirmation in SAP. Material issue will be performed in the SAP after the cut-over date. If stock take of raw material take place on the cut-over date, we must take care to add back the raw materials which issue has been withheld. For the purpose of general ledger, we will manually compute an accrual and reversal entry to ensure that proper cut-off are observed for accounting purposes. The entry to put through to FY19XX in the old GL system prior to its conversion is to Dr WIP, Cr Raw Material (for the material component) and to Dr WIP Cr Manufacturing cost for the labor component. The reversal entry for FY19YY should be Dr Raw Material Cr WIP (for the raw material component) and Dr WIP Change account Cr WIP for the labor component.@ www.sap-img.com Page 73 of 79 SAP Version 4.6c
  74. 74. A Step-by-Step Guide to the SAP PP Shop Floor Control ConfigurationsAppendix A: The Production Order Status Business Process FlowThe Production Order Status refer to the business process flow of the current ProductionOrder. This is a way for the system to control the different activities of the user on theProduction Order.An example of a Production Order Business Process Flow:1. A Planner User convert the Plan Order to a Production Order, the initial status will be CRTD. The status CRTD means that this order is not firm for Production.2. The Production User will not be able to Print Out the Production Order until the Planner User Release it which will change the status to REL.3. The Planner User Release the Production Order (CO02 – Functions – Release) and the Production User will be able to print out the Production Order (CO04N) for actual Production. After printing the Shop Floor Paper, the order will include the status PRT to inform the user that this order have been printed.4. Actual Production started and upon completion the Production User will input the Production information which they have collected and written on the Shop Floor Paper into the SAP system. This is called Production Confirmation (CO11). An Order which is partially completed, will include the status PCNF. Once it is Fully completed, the status will change to CNF.5. A fully completed production order means that the materials has turned into a Finished Product which is really to be ship to the Customer. The Delivery User will receive the fully completed Production Order (which is the Finished Product - MB31) into his warehouse and he can then delivered it to the customer. Finally, the status will include DLV which means that the whole Production Order process have been completed.6. In cases where the Production Order was stopped due to the Customer Order Cancellation, the Production User can closed the Order by setting the status to TECH (CO02 – Functions – Restrict Processing – Technically Complete).@ www.sap-img.com Page 74 of 79 SAP Version 4.6c
  75. 75. A Step-by-Step Guide to the SAP PP Shop Floor Control ConfigurationsA Sample of the SAP Production Order Screen – CO01/CO02@ www.sap-img.com Page 75 of 79 SAP Version 4.6c
  76. 76. A Step-by-Step Guide to the SAP PP Shop Floor Control ConfigurationsAppendix B: How to make enquiry on Open Production Orders?Transaction : SAP Menu Path : Logistics – Production – Production Control –COOIS Information System - Production Order Information SystemThe default enquiry is by Order Headers. You can make enquiry by Operations if youwant to by changing the List Profile. To list the Open Production Orders, make used ofthe System Status and exclude all status with CNF (Confirmed) and DLV (Delivered).@ www.sap-img.com Page 76 of 79 SAP Version 4.6c
  77. 77. A Step-by-Step Guide to the SAP PP Shop Floor Control ConfigurationsAppendix C: What is Backflushing and Where is the Indicator Set?In SAP context, Backflushing means to consumed those Materials that have been usedduring the course of the Manufacturing Process. To produce something, raw materialsmay be required. With reference to the Bill of Materials, the Purchaser will buy thosematerials based on the requirement prompt by the SAP MRP system. Upon finishing theManufacturing Process, raw materials will be used up to produced the Finished Goods forthe Customer.The Planner will determined at which Production Operation will this components beconsumed and set the Backflushing indicator accordingly.To set the Backflushed Indicator: Transaction : SAP Menu Path : Logistics – Production – Master Data – Routings – CA01/CA02 Routings – Standard Routings – Create/ChangeAssuming that you have built the BOM and input the Work Center for each Operations.This is the first screen when you enter CA02. Now, click the CompAlloc button.At the CompAlloc screen, you will see the Backflushing Indicator. A tick will indicate thatthe Components will be deducted when the Production User do the ProductionConfirmation. If the Backflushed Indicator is grey, this mean that Backflushing havenot been assigned. To assigned it, click the New assignment button.A New assignment screen will pop-up. Just input the Operations that you want theComponents to be Backflushed. When the Planner create a Production Order, thesystem will read the Routing Master data and copied all this information to the ProductionOrder.@ www.sap-img.com Page 77 of 79 SAP Version 4.6c
  78. 78. A Step-by-Step Guide to the SAP PP Shop Floor Control ConfigurationsUltimately, it still the Production Order will decide which Operation will the Componentsbe Backflushed.At the First Screen in CO01/CO02 – Production Order Create/Change, click theComponents Overview button.The Backflushed Indicator will be copied from the Routing but the Planner still canchanged it in the Production Order.@ www.sap-img.com Page 78 of 79 SAP Version 4.6c
  79. 79. A Step-by-Step Guide to the SAP PP Shop Floor Control ConfigurationsChecking the Backflushing Goods MovementWhenever the user post a confirmation with CO11N, the backflushing components goodsmovement will be tied to the production order. You can check them with TcodeCO02/CO03 by clicking the menu Goto – Documented goods movements.@ www.sap-img.com Page 79 of 79 SAP Version 4.6c

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