IDES MC Cem PP Bulked

Cement - Production Planning (bulked)
Purpose
In the bulked cement scenario the goods are kept in readiness in silos. The orders are created
immediately after the order inflow. Immediate availibility is asumed on all input components and the
credit limit is checked. Conditions are maintained per customer and per building site, if this is
necessary. The master data of materials contains standard prices for consumers and customers.
In the production execution the production type of repetitive manufacturing is used. The production is
initiated when the stock falls short of the safety stock.
The outbound delivery will be created with reference to the order. Actual delivered quantities and other
delivery relevant informations will be transmitted via an interface from an external scale. These
informations will be feed into the outbound delivery. The connection of the scale is simulated by a
simple report.
Goods issues will be posted and the weighed quantities will be invoiced. It is possible to create the
outbound deliveries automatically, goods issues and the creation of invoices can be executed by a
collective billing run.
System Landscape
System Landscape, this Process is built in
SAP for Mill Products => find system: IDES System Landscape Viewer
Solution Components used in this Process

Enterprise Portal
R/3
SCM
Users
The scenario can be run with a predefined user ID. This is an option if you don’t want to create an
individual ID via self-service in SAPNET. The following data can be used to log on:
Predefined User (Role) Password Client Component
MILL_DEMO welcome Enterprise Portal
MILL_DEMO welcome 720 R/3
MILL_DEMO welcome 720 SCM
If a scenario needs a special user ID it is mentioned in the scenario documentation script.
Process Flow
1. Change the Material Master
2. Check Stock/Requirements List
3. Execute MRP
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IDES_MC_Cem_PP_bulked.doc, 8 December 2005, ID: 10000002648
4. Confirm Production
5. Postprocesssing Goods Movements (optional)
6. Confirmation Effects
7. Additional Information
8. Post Stock
Production Materials
Sales
Planning Management
Undershooting
Undershooting
Sales
Sales Order
Order of
of Safety
Safety Stock
Stock Purchasing
Purchasing
Entry
Entry
Production
Production
Execution Inbound
Delivery
Delivery Creation
Creation Execution Inbound Delivery
Delivery
Scale Scale
Simulation Simulation
Backflush
Backflush
for bulked Transportation
Transportation Repetitive
for bulked
Planning Repetitive Goods
Goods Receipt
Receipt
goods Planning Manufacturing goods
Manufacturing
Picking Invoice
Picking Invoice Verification
Verification
Goods
Goods Issue
Issue
Billing
Billing
documente here
Additional Process Information

1. Planning
The planning in this process is simply based upon repetitive manufacturing with one product
cost collector per material. There’s no need for the use of the planning table. The production
controller gets his information to produce either with the exception in the stock requirements
list (‘Stock fallen below safety stock level’) or when he checks the stock overview per material.
2. Bill of Material (BOM)

There is only BOM per material.
3. Routings
Every product group (bulked cement and cement in sacks and concrete) has it’s own routing.
There’s only one variant for each group.

Data Used in this Process
Field Data US Data EU
Plant M210 M110
Material MC_POCTLO_21 MC_POCELO_11
MC_CLAY_21 MC_CLAY_11
MC_FLYA_21 MC_FLYA_11
MC_SAND_21 MC_SAND_11
Work center(production line) MC_QU21 MC_QU11
MC_CR21 MC_CR11
MC_RD21 MC_RD11
MC_KI21 MC_KI11
MC_CG21 MC_CG11
MC_PL21 MC_PL11
Work center MC_MP11
Routing MC_POCTLO_21 MC_POCELO_11
Bill of material MC_POCTLO_21 MC_POCELO_11
Production version 0001 0001
Prerequisites
Plant M210 M110
Stock 200 200
Safety Stock 250 250
Component MC_SAND_21 MC_SAND_11
Stock 20 20
Component MC_FLYA_21 MC_FLYA_11
Stock 20 20
Component MC_CLAY_21 MC_CLAY_11
Stock 20 20
To use the following scenarios you have to post stocks for the used materials

Demo
Change the Material Master

1. Log on to the R/3 system with user ID MILL_DEMO and password welcome.
2. In the R/3 system choose Logistics → Materials Management → Material Master → Material →
Change → Immediately.
Or use transaction code MM02.
3. Enter the following data:
4. Choose Select view(s).
5. Select MRP2.
6. Choose .
7. In the Organizational Levels dialog box, enter the following data:
Plant M210 M110
8. Choose .
Field Data
Safety stock 250
10. If necessary choose .
Check Stock/Requirements List

1. In the R/3 system choose Logistics → Production - Process → MRP → Evaluations →
Stock/Requirements List .
Or use transaction code MD04.
Plant M210 M110
3. Choose .
The system displays the actual stock/requirements list.

Execute MRP
Use
You now execute multi-level requirements planning for the finished product MC_POCELO_XX, and
then check the results. You check whether the undershooting of the safety stock is transferred
correctly into a planned order.
1. In the R/3 system choose Logistics → Production - Process → MRP → Planning → Single-Item,
Multi-Level.
Or use transaction code MD02.
Plant M210 M110
Processing key NETCH NETCH
Create purchase req. 2 2
Delivery schedules 3 3
Create MRP list 1 1
Planning mode 3 3
Scheduling 1 1
Also plan unchanged X X
components
Display material list X X
3. Choose .
4. To confirm the warning message choose .

The statistics overview appears.
5. Choose Materials.
The system displays the overview of the planning results.
6. Select the first item in the list and choose Selected results.
The system displays the planning results based on the planned orders generated during MRP for
the finished product.
7. Choose .
8. In the dialog box, choose Yes.
Confirm Production
In the repetitive manufacturing process there’s no need of a production order, the produced amounts
simply have to be backflushed. This is done with the following transaction.
1. In the R/3 system choose Logistics → Production → Repetitive Manufacturing → Backflush →
REM Backflush.

Or use transaction code MFBF.
Backflush qty 10 10
Plant M210 M110
Prod. version 0001 0001
3. Choose Post with correction.
4. Choose .
The system displays the materials (BOM components) proposed for backflushing on the Final
Backflush screen.
If there is a shortage of components, the Backflush Errors dialog box appears. You can change
the backflushed quantities and/or materials or, if you want to process the backlog at a later time,
push ‘Enter’ without selceting any item.
The current BOM is exploded. An existing component scrap is taken into account.
5. Choose .
The system issues a message informing you that the goods receipt (GR) for the product and the
goods issues (GI) for the backflushed components have been executed.
6. To leave the REM Backflush – Transaction variant: None screen choose .

The system creates a backlog record containing the missing components and quantities.
Postprocesssing Goods Movements (optional)
You only need to carry out the following steps if the goods movements must be
postprocessed. Otherwise, you remain on the REM Backflush - Transaction Variant:
None screen and continue with the Effects of the Confirmation section.
1. In the R/3 system choose Logistics → Production → Repetitive Manufacturing → Backflush →
Postprocess → Postprocessing List.
Or use transaction code MF47.
Plant M210 M110
3. Choose .
The system displays all of the failed goods movements.
4. To post this record without changing Select the record/records and choose Postprocess Selected
Postprocessing Recs.
If you want to change the record (e.g. the quantity) choose Change selected
postprocessing record and enter the different data.

5. Choose .
Confirmation Effects
1. In the R/3 system choose Logistics → Materials Management → Inventory Management →
Environment → List Displays → Materials Documents.
Or use transaction code MB51.
Plant M210 M110
Storage location M210 M110
3. Choose .
4. Double-click on the material document you want to see in detail.
Additional Information
To display additional information concerning the bill of materials and the routings execute the following
transactions.
1. To display the bill of material in the R/3 system choose Logistics → Production → Master Data →
Bills of Material → Bill of Material → Material BOM → Display.
Or use transaction code CS03.
Plant M210 M110
BOM Usage 1 1
3. Choose Item.
4. Choose .
5. To display the routing choose Logistics → Production → Master Data → Routings → Routings →
Standard Routings → Display.
Or use transaction code CA03.
6. Enter the following data.
Plant M210 M110
7. Choose Operations.
8. Choose .

Post Stock
Usage
During this process you deliver specified materials to customers. In the first process step, you ensure
that there is sufficient stock to fulfil these deliveries. As the procurement process is not of absolute
interest to this process, you post the stock without reference to any upstream production or purchase
order. The materials involved are managed in batches. You therefore need to specify the
characteristics of the batches that are posted to.
Procedure
1. In the R/3 system choose. Logistics → Materials Management → Inventory Management →

Goods Movement → Goods Movement (MIGO).
Or use transaction code MIGO.
Action Goods Receipt Goods Receipt
Reference Document Others Others
3. Choose .
4. Choose tab strip Quantity.
Qty in unit of entry 200 200
6. Choose tab strip Where.
Plant M210 M110
Storage location M210 M110
8. Choose .
9. Choose .
If you need to change the stock because of to much material in-stock you can use the
same transaction with movement type 201.


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Cement - Production Planning (bulked)

Solution Components used in this Process

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Additional Process Information

2. Bill of Material (BOM)

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Change the Material Master

10. If necessary choose .

Check Stock/Requirements List

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4. To confirm the warning message choose .

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3. Choose Post with correction.

6. To leave the REM Backflush – Transaction variant: None screen choose .

Postprocesssing Goods Movements (optional)

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1. In the R/3 system choose. Logistics → Materials Management → Inventory Management →

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