Master Data : Overview Master Recipe Resource Material BOM Batch Batch Batch . . .
Material Substance or commodity that is bought or sold on a commercial basis, or is used, consumed, or created in production; a material can also be a service Material
Material Master Overview
Each material is maintained in a Material Master record
The Material Master is organized by views or specific screens where similar data is entered
For example, with sourcing, the MRP, Purchasing and Accounting views are the most important
Each plant can have its own plant-specific data for the same material
For example, MRP - reorder point, Purchasing - purchasing group, Accounting - moving average price
Material Master Data
Master Data for materials is stored in the Material Master
T he Material Master is comprised of data records that contain all the basic information required to manage a material
Material Masters may be deleted yet can remain on the SAP system for historical purposes
SAP Material Master Material Master Data
Material Master and Other SAP Modules Material Master Production Planning (GR/GI) Supply Chain (GR/GI) Reqn & PO FI/CO (Costs) Sales & Distribution (GR, GI) Plant Maintenance (GR, GI) Safety & Sustainability (GR, GI) Project Systems (GR, GI) IM & WM (GR, GI Transfers)
Views in the Material Master Material Master MRP 1,2 Stocks in plant/warehouse Accounting 1,2 Plant / Storage Loc. Stock Basic Data Plant Stock Forecast Plant Data / Storage Sales and Distribution Purchasing
Bill of Material (BOM)
Bill of Material : Definition
A BOM is a complete, formal structured list of the components that make up a material or an assembly
Unit of measure of each component
A BOM is a central source of data for various production planning activities
MRP calculates component quantity requirement for specific dates
Process Order management use BOM to plan material provisions
BOM Usage BOM Construction/ Technical Data Costing/Price Production/ Operations Plant Maintenance/ Location Data Sales/ Order Quantity Sales Order
BOM Structure Item Header Item
+ = Input material
- = Output Material
General Long Text
Example : 7000F PRIME V.001 8500-0000014 Ethylene 1,088 Kg. 8500-0000011 Butene-1 8.992 Kg. 8500-0000016 Hydrogen 8.992 Kg. 7505-1000005 PZ-CAT 0.106 Kg. 7505-1000002 AK-STABILIZER 0.512 Kg. … 7000F PRIME V.001 Base qty: 1,000 kg. Product Mat. Components BOM Header BOM Items
Multi Level BOM Ethylene Hydrogen PZ Cat. HD 7000F Prime 25 Kg. 7000F Semi V.001 Bag 25 Kg Pallet Level 1 Level 2
Reporting Which BOM contains … ? ? ? ? ? BOM explosion Where-used list Print
The BOM explosion answers the question: What does a product consist of? This question arises in various situations, such as when:
You need to determine requirements for a product
The engineering department needs to look at the overall structure of a product
You need an overview of all the necessary parts and materials
You need to calculate costs or effects of cost changes
Res - a Res - b A9 A10 Mother a Intel 500 BA - C Mother b XYZ Solder-1 1 1 1 2 2 .005 1 1 2 2 3 3 .005 1 ABC
The where-used list provides an answer to the question:
Where is a material used and in what quantity?
This question arises especially where there are a lot of multiple-use parts and materials.
Examples of why the information is required are:
- To calculate the requirements for a particular material.
- To find the products that are affected by changes to the individual parts.
- To find the assemblies produced late due to delayed delivery of a raw material for example.
- To calculate the cost effects on a product if raw materials costs change.
Res - a Res - b A9 A10 Mother a Intel 500 BA - C Mother b XYZ Solder-1 1 1 1 2 2 .005 1 1 2 2 3 3 .005 1 ABC
Bill of material : Summary
Bill of M aterial contain s important basic data used in many different organization areas .
Unit of measure of each component
BOM data is important for:
Material staging during production
BOM Maintenance (CS01, CS02, CS03)
Logistics Production Master Data Bills of Material Bill of Material Material BOM Create / Change / Display
BOM - Header Base Quantity BOM Status Base Unit ( Same unit as UOM in Material Master)
Material Master – Main Product Co – Product Indicator Cost Allocation
Material Master – Joint Production Cost Proportion to be allocated Main Product & Co-Product Assignment Assignment Structure
BOM Level by Level (CS11) Multi Level BOM (CS12) Summarized BOM (CS13) Plant Material Alternative BOM BOM Application
CS11 CS12 CS13
BOM explosion report – To show Component or Structure of product (Top Down) Consists of
Structural (BOM level by level (CS11)
Multi-level BOM (CS12))
Quantity-based (summarized BOM)(CS13)
BOM Comparison (CS14) Plant Material Usage Alternative
BOM Comparison Report – To compare 2 Product in Case of
1. Comparing Alternative BOM
2. Comparing BOM of different Product
The BOM comparison is useful if:
- Several BOMs exist for a material,
- With different uses,
- And/or with different change statuses.
The comparison can be single-level or multi-level.
You can select which fields you want to compare.
BOM Comparison (CS14)
Where-Used List BOM (CS15) Component Direct Material BOM
Where-Used List BOM (CS15) Plant
Where used list - Material Where Used List report – To show the components that use in which product and how much quantity (bottom-up) Single-level Multi-level The system only determines the BOMs where the material is used in directly as a component. The BOMs are all shown with explosion level 1.
The system will display where the BOM is used at any level. A BOM that contains the material directly is shown with explosion level 1. If the material is used in sub-assemblies, the list explodes the entire BOM hierarchy, with a number showing the successive explosion levels.
Change Document BOM (CS80) Material Plant BOM Usage
Change Document BOM (CS80) DATE Default date = Today’s date - 90 days
Change Document BOM (CS80)
Refer to this information for your exercises:
System ID CEQ/620 User ID Your own SAP user ID Exercises PP-01 Data Preparation
Resource : Definition
Resource are essential master data for Production Planning
A Resource is an organizational unit that has a specific capacity that defines when an operation must be performed
The activities performed at the Resource are valuated by charge rates which are determined by cost centers
Resource indicate where and by whom work is carried out at each stage of production
Resource have a finite capacity to perform a task
Resources Means of production and persons in the production process which have capacities assigned to them. Resources are subdivided into resource categories. Resource Processing Unit Labor Waste disposal facility Energy Transport
Resource Code Structure (8 Char.) Running Number Utility type/ Labor type /Production Unit X - XX 1 = Main Resource, 2 = Secondary Resource, 3 Secondary Resource (Sim. Cost) XXXX Description TEX reactor 01R001 TEX Electricity HDPE Batch Process HDPE Bagging Process Resource Code 1REAC-01 2ELEC-01 1PROC-01 1BAG-01
Primary Function of Resource Resource Scheduling Data and Available Capacity Costing Data Default Values for Task Lists Task Lists 2724,00 1200,00 124,00 4048,00 Costing Lead Time Scheduling, Capacity Planning
Resource Usage All Task List Types All Task List Types Master Recipe and Process Order Master Recipe & PO Only Maintenance Task Lists Maintenance Task List Only Networks Network Only Master Recipes Master Recipe
Relationship between Resources and Operation Operation 10 Activity Types Default Values Control Key Standard Value Key
Cost Center / Activity Type / Resource Production SET $20 per LAB $40 hour MAH $40 kWh $20 Set-up Labour Man Hours Kilowatt Hours Costs for In-House Production Set-up PP-SET Machine PP-MAH Labour Milling Unit 5 Lathe P7 Saw 2 10 20 30 40 Cost Center Activity Types for the Cost Center Resource with Activity Types Recipe with Standard Values
Evaluations (Reports) Resource List Cost Center Allocation Change Document Resource Where-Used List Resource Capacity
Resource : Summary
Resources are means of production and persons in the production process which have capacities assigned to them.
A resource can have several capacities allocated to it.
To calculate costs, execution time and capacity requirement, formulas can be defined for resources
Resource Creation Basic data Description Person Responsible Usage Standard Value Key
Resource Creation Default values Control Key Standard Value Unit Standard Text Key
Resource Creation Capacities Capacity Category Other Formula * * Note : Only main resource required
Resource Creation Header Description Capacity Planner Group Base Unit Capacity Utilization No. of Individual Capacities Factory Calendar = T2 Start /Finish /Break time
Resource Creation Scheduling Capacity Category Other Formula * * Note : Only main resource required
Resource Creation Cost center assignment Cost Center Activity Type Formula Key
Resource List (CR05) Plant
Resource List (CR05)
Cost Center Assignment (CR06) Plant
Cost Center Assignment (CR06)
Where-Used List Resource (CA81) Resource Plant Overview Var.
Where-Used List Resource (CA81)
Change Document Resource (CR10) Plant Resource
Change Document Resource (CR10)
Master Recipe are an integral part of Production Planning
Enable the manufacture of products
Used as the path or work steps to complete Process Orders
Contain information about the following that relates to the manufacture of a product:
Sequence in which the operations should be performed
Resource with the manufacturing activities
Master Recipe is a description of the production process used to manufacture plant materials or provide services in the production industry
Structure of a Master Recipe Operations Process instructions PI characteristics Inspection characteristics Resource network Recipe header Relationships Phases Primary resource Secondary resource Material Components Material (product)
Functions of a Master Recipe Operations Process instructions PI characteristics Recipe header Phases Resource Master Recipe Process Order MRP Cost accounting
Phases are structured hierarchically under an operation. They are used to obtain a more detailed planning view for one operation and for the generation of control recipes. Both operations and phases are used for capacity planning and costing.
During process planning, scheduling is always carried out on the operation and phase level.
Master recipes contain the operations necessary to carry out production.
Operations can be broken down into phases. Phases describe the activities during an operation on a more detailed level
Resources can be allocated to operations or phase. The resource allocated to the operation is the primary resource and is automatically the primary resource for each of the phases within that operation. Besides the primary resource, further required resources can be allocated to an operation or phase.
Each material list component can be allocated to one operation or phase. When a process order is released, any non-allocated components are automatically allocated to the first operation.
Recipe Maintenance (C201, C202, C203)
Logistics Production-process Master data Master recipes Recipe and Material List Create / Change / Display
Recipe Group Recipe
Recipe Creation Header Description Status Usage Default Base Qty at Operation level
Recipe Creation Operations & Phase Main Resource Destination = G1 Superior Operation Phase Indicator Double Click (20)
Recipe Creation Phase details Base Quantity Standard Value Secondary Resources Standard Value Unit Activity Type
Recipe Creation Secondary Resources Base Quantity Standard Value Standard Value Unit Activity Type
Recipe Creation Material Assignment Material Plant Recipe Counter
Delete Recipe – Without Archiving (C298) Material Plant
Delete Recipe – Without Archiving (C298) Select Master Recipe to DELETED
Recipe List (C251) Plant Material Task List Type
Recipe List (C251)
Recipe Change (C260) Plant Task List Type = 2 Recipe Group Material
Recipe Change (C260)
Change Document Recipe (C261) Recipe Group Period
Change Document Recipe (C261)
Master Recipe Practices
A production version determines which alternative BOM is used together with which task list/master recipe to produce a material or create a master production schedule.
For one material, you can have several production versions for various validity periods and lot-size ranges.
Production Version Production version BOM Master Recipe
Production Version (C223)
Logistics Production-process Master data Production Version
Plant Material Create
Production Version (C223) Material Description Production Version CHECK Task List Type Recipe Group Recipe Group Counter Alternative BOM BOM Usage
Production Version List (C252) Material Plant
Production Version Practices
Engineering Change Management
Changes to objects (i.e., BOM, Master Recipe etc.) can be carried out with or without history in the SAP system. This history can be captured using engineering change management.
Change without history
During the time a product is being developed and may be subject to many changes, these are not documented. This continues until you decide the product has reached a “Live” state.
Change with history
These are changes that may require follow-on activities in the company and that have to be documented (for example, Material Master change BOM change). The status of the objects before and after the change is stored. Engineering change management makes continuous documentation of changes possible.
Engineering change management provides the following functionality:
It allows the user to document the reason for a change.
It provides the ability to plan changes for objects in the future.
Engineering Change Management With History Tracking Without History Tracking 2008
Documentation of a Change When does the change occur? What is the status before the change? After the change What was the reason for the change A B C B D A 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
Logistics Production-process Master data Engineering Change Management Change Number Create / Change / Display
Change Master Header Change Description Change Reason Valid from date Change Status 1 = Active 2 = Inactive Change Reason
Example – Change BOM (with Change No.) Change No. Date will be automatically change to “ VALID DATE in Change No.”
Example – Change BOM (with Change No.) Detail description of this Change
Example – Change BOM (with Change No.) After Change at any item, system will display CHANGE NO . at that item After Change at any item, system will display CHANGE NO . at that item Change Effective Date
BOM Display Old Value (Valid to date change New value (Valid from date change
Information System (CC07)
Valid from / to
Logistics Production-process Master data Engineering Change Management Reporting Information System