Documenti di Didattica
Documenti di Professioni
Documenti di Cultura
Overview of SAP PP
1/7/2018 2
Over view of SAP PP :
PP Module in SAP deals with planning and manufacturing process. Basically there are three types of
manufacturing process handled in SAP.
Discrete manufacturing
Various products are made in different qty with frequent changes in processing
Example : Eng Industries, Industrial valves,battery and Textile & Apparel industries
Method : Entire Mfg activities are handled through " Production Order'.
Repetitive Manufacturing
Similar products are produced over a long period of time with least or no changes in process
Example : Bottling plant, automobile manufacturing
Method : Entire Mfg activities are handled through " Planning table through Planned Order'.
Process Industries
Its similar to discrete manufacturing
Example : Manufacture of Dairy products and chemicals
Method : Entire Mfg activities are handled through " Process Order'.
1/7/2018 3
1/7/2018 4
The Planning Process consists of six basic steps as seen in the diagram above.
1 Planning of expected sales quantity and production quantity done by sales in discussion
with planner
5 System generates planned order for required quantities for both component and finished
products.
1/7/2018 5
1/7/2018 6
The Production Process again involves six basic steps as listed in the above
diagram:
4 Reporting to the SAP system is done through confirmation. Raw materials are issued
through backflush and activities are recorded.
6 Final product is received in to the respective storage location and ready to sale.
1/7/2018 7
1/7/2018 8
Integration in SAP PP Module with other module
2. Material Requirement Planning is done by the system which takes input from
purchasing, warehouse, quality and production modules.
3. During production execution, quality module checks the final product. Costing
department analyze the cost of production.
1/7/2018 9
Integration in SAP PP Module with other module
Case 1. Let’s say we have purchased raw materials necessary for production and we
need to issue these to the shop floor.
Handled by SAP: There are three documents, which will be passed simultaneously in
SAP.
a) Material Document: A goods issue document is passed which reduces the stock from
raw material storage location. This is a quantity updation.
c) Controlling Document: The Production order is debited with the raw material costs.
1/7/2018 10
Integration in SAP PP Module with other module
Case 2:
Let’s say that the production is now complete and requires inspection.
Handled by SAP:
While posting a goods receipt in the SAP system, stock will be first posted to the
quality stock. The quality guy after physically inspecting the stock will release the
quality stock to unrestricted stock in SAP.
This then makes the stock available for sales. The sales cannot take place while the
material is in the quality stock.
1/7/2018 11
Terminologies in PP module
Work center : Machines may be referred as work center. It is defined as the place where
operations are carried out. Apart from machine, group of person (e.g. in maintenance
department, certain group of people may be employed for any machinery movements etc..)
may be treated as a labor work center
Planned order : It specifies when the material is to be produced and the quantity to be
produced. It may also be referred as preparatory step towards production. Production
information is available in Planned order and it will be transferred to production order.
Production order : Entire manufacturing activities are accounted in the system through
production order. It is suggested to create production order from planned order. All
subsequent activities in production are carried out only with reference to the production
order.
1/7/2018 12
Confirmation :
Reporting of
How much yield, scrap and rework
Quantity of work done
Which work center is used
Who has done it
Above reporting is done with respect to production order.
Backflush :
Issuing of raw materials components to shop floor automatically during
confirmation.
1/7/2018 13
Status - Created :Status of production order indicating that the production order is
created.
Status – Released :This status of production order indicates that the actual
production is started.
Settlement :It is related to accounts, it is settling of all the cost collected in one
particular production order to the material. Normally it is done by accounts and at
times by production also.
1/7/2018 14
Float Before Production :Number of days to be counted before the actual start date of
production. It is a additional timing used for scheduling
Float After Production : Number of days to be counted after the actual finish date of
production. It is a additional timing used for scheduling
Standard value key :Key contains the activities for each work center. A standard value
key can have Maximum of six activities.
MRP Type :It indicates how the material is to be planned. i.e whether the material is to
be planned by MRP, consumption based planning or through MPS.
1/7/2018 15
MRP : Material Requirements Planning is a process where BOM of all
products are exploded and shortages and requirements are calculated. MRP run
will consider purchase order, purchase requisition and quality stock.
1/7/2018 16
Master Data in SAP PP - DISCRETE MFG :
1/7/2018 17
Master Data in SAP PP - REM :
1/7/2018 18
Master Data in SAP PP-PI :
1/7/2018 19
There are three very essential master data in PP module.
Bills Of Material
Work center
Routing
Work center:-
Machines may be referred as work center. It is defined as the place where operations are
carried out. Apart from machine, group of persons (e.g. in maintenance department, certain
group of people may be employed for any machinery movements etc.) may be treated as a
labor work center.
Data in work center determines
Scheduling – start and end of operation
Costing – Cost incurred during production
Capacity planning - to plan the required capacity
1/7/2018 20
Routing:-
It contains
1/7/2018 21
DEMAND MANAGEMENT
Demand Management helps you to determine requirement quantities and date for
finished products.
Customer Demand
PIR (Planned Independent requirement)
1/7/2018 22
PLANNING STRATEGY
Planning Strategy
Planning Strategy represent the business procedures for the planning of production qty's and dates
1/7/2018 23
MAKE TO STOCK CONCEPT
1/7/2018 24
MAKE TO STOCK CONCEPT
1/7/2018 25
STRATEGY 10 VS 11
1/7/2018 26
MAKE TO STOCK CONCEPT
Strategy No : 40 - Planning with Final Assembly
This strategy will consider both the customer requirement and stock requirement
I.e PIR while planning. PIR in the DM are reduced only when the sales is completed.
Pls note that sales order will consume the PIR . i.e 100 nos planned qty will not be sufficient to meet the requirement; hence planned
order of 120 will be created by MRP
1/7/2018 27
1/7/2018 28
MAKE TO ORDER CONCEPT
This strategy will consider only the customer requirement while planning. PIR in the DM are NOT CONSIDERED during planning
Note : For a product having strategy 20, it is not possible to plan through PIR
1/7/2018 29
Planning
Three important way of planning is used in SAP. They are
1/7/2018 30
Material Requirement Planning
Planning Procedure:-
There are three major Planning procedures,
1. Material Requirement Planning (MRP)
2. Master Product Scheduling (MPS)
3. Consumption Based Planning (CBP)
1/7/2018 31
MRP IN SAP
1/7/2018 32
MRP Integration and components:-
Work center and routing are required to determine the production start and end dates
1/7/2018 33
Process Flow in MRP
1/7/2018 34
Production Process:-
1/7/2018 35
1/7/2018 36
Production Order:-
1/7/2018 37
PRODUCTION ORDER STATUS IN SAP
Technically completed (TECO) – Order processing is over, ready for month end
processing by accounts
1/7/2018 38
REPORTS IN SAP
StandardList Reports
Reports which will only display the data. No transaction can be performed through this report display is known as standard list reports.
This reports is used to
Example : Display " Master data related information" Such as MM03,CR05…etc
Worklist Reports
Reports which will allow user to perfomtransaction while displaying the report is known as Worklist reports.
This report is used to display and work with production orders.
Example : COOIS - Production order information system.
1/7/2018 39
EXAMPLE : REPORTS in SAP
1/7/2018 40
Thank You
41