Configuring Make-to-Stock – Process Manufacturing Based on Process Order (BJ8)

You use this configuration item to define a collection of default values for master recipes. When creating or changing a master recipe, you have to enter a profile. The values of this profile are proposed as default values in the new recipe or the new recipe objects. You can either accept or overwrite these values.

In a profile, you can specify default values for the following areas:

• General recipe data such as control keys
• Increment between operation numbers

Note

• Profiles can also be maintained within recipe maintenance. In this case, the changes are only valid until you leave the respective recipe.
• Certain data can also be copied from a material or from a resource to the master recipe. Values that have been maintained in the material or in the resource take precedence over values from the profile.

1. Determine the default values that can reduce maintenance work in your company.

2. Create the respective profiles and maintain the corresponding default values.

You use this configuration item to assign orders to order types. You have to assign every order to an order type. The order category (= 40, process order) is a fixed setting and cannot be changed. The order categories are predefined in the SAP system and characterize the technical properties of the orders. The order category defines, for example, the transactions you can use to process an order.

The order type defines the following:

• Order residence time

  You define how long completed orders remain in the SAP system before they are archived.

• Status management

  An order can run through several statuses. The status controls which business-related operations are permitted with an order.

• Number assignment

  You have to assign a number range to each order type. If you create a new order type by copying an existing one, you can either keep the number range assignment or choose a different one.

Note

In addition to the general order parameters at client level, there are also parameters at plant level, which you can process in the configuration step under Shop Floor Control → Master Data for Process Manufacturing → Define Order-Type-Dependent Parameters

Order types are preset in the standard delivery of the SAP System.

1. Classify the orders with regard to their defining characteristics (for example, order category or number range).

2. For each order category, define whether you want to use status management.

3. If necessary, define your own order types. To do so, copy an existing order type and adjust the data as necessary.

You use this configuration item to define the parameters that are valid for each order type and plant.

The parameters are split up as follows:

Here, you define the data that influences master data selection or order master data maintenance. The screen contains the following indicators:

• The production version defines if the production version is selected automatically or manually.
• The recipe selection ID defines the priorities according to which the recipe is selected.
• You can activate the entry tool for operations to help you when you create operations.

General

• Substitute MRP controller/substitute production supervisor. These are proposed when you create process orders if an MRP controller or production supervisor are not specified in the material master, or if there is no reference to material.
• Reservation/Purch.Req. specifies whether certain order objects (operations, components) are relevant to MRP.
• Collective requisition enables collective purchase requisition per orderfor externally processed operations or non-stock items.

Bill of Material

• Application defines how the BOM alternatives are selected
• Batch determination
• Search procedure defines how batch determination is to take place

Quality Inspection

Inspection type defines how a quality inspection is to be carried out

• Status Change Documents
  • Here, you define whether you want change documents to be written if a status change occurs. You also define the level at which the change documents are written:
  • A status change document documents the following:
    • Which status has been changed
    • Who changed the status
    • Whether the status has been activated or deactivated
    • In which transaction the status change has been carried out
  • In the process order, you can define the status at the following levels:
    • Order header
    • Operation
    • Material component
• Status change documents can thus be defined independently of each other, at each of these four levels.
  Note

  If you have defined these parameters such that status change documents are written for a particular order level, the SAP system only writes a status change document for a status change from this point in time if the order (or operation/component) has been created since the status change documents have been activated.
• Documentation of Goods Movements

  You can specify that goods movements are to be documented with reference to an order.

• Cost Accounting

  Here, you define the parameters relevant for cost accounting, such as costing variants for planned and actual costs and a results analysis key.

• Distribution Role

  Default (distribution) role defines an automatically generated distribution role for CO settlement.

You use this configuration item to create production scheduling profiles for specific plants.

In a production scheduling profile, you can:

• Specify that certain business transactions or processes are to be carried out in parallel in a production or process order:
  • Order release at the time the order is created
  • Generation of document link from the material master when the order is created
  • Generation of document link from a BOM when the order is created
  • Scheduling upon order release
  • Generation of document link from the material master upon order release
  • Generation of document link from a BOM upon order release
• Specify whether only partial quantities are to be confirmed at the time of an availability check
• Specify that an automatic goods receipt is to take place
• Specify that in the case of the confirmation:
  • No short quantities are to be updated
  • No excess quantities are to be updated
  • Neither short nor excess quantities are to be updated
  • An adjustment of the operation and component quantities to the actual values is to take place
• Make various specifications in the area of batch management:
  • Automatic batch creation when an order is opened
  • Branching to batch classification when a batch is changed
  • Extended batch classification via Customer Function Call
  • Generation of a batch split record in the production order for each batch that is found
• Specify settings regarding transport:
  • Specify that only transport requirements are to be created if transport requirements can be generated for all the components of the operation
  • Specify that either the committed quantities or the required quantities are to be taken into account when transport requirements are generated
  • Specify that the creation of transport requirements is to take place automatically
• Specify which order type is to be suggested depending on the business process
• You can assign a production scheduling profile to a:
  • Material (Work Scheduling screen in material master)
  • Production supervisor

Note

• The assignment to a material takes higher priority.
• The production scheduling profile is adopted in the production or process order at the time the order is opened.

1. Create the necessary production scheduling profiles.

2. Assign the profiles to the appropriate materials or production supervisors.

You use this configuration item to define the production supervisors for your plants. In addition, you can assign a control profile to each production supervisor. By assigning production supervisors to materials within the application, you can define responsibilities for a material within production activity control.

1. Create your production supervisors.

2. If necessary, assign profiles to your production supervisors.

You use this configuration item to define parameters for the automatic stock and batch determination for each plant, order type, and business transaction. You can assign a stock determination rule and switch off stock or batch determination.

The business transactions for production orders are:

• Backflushing of components for confirmations
• Picking
• Batch determination

1. Enter the plant, order type, and business operation.

2. Enter the type of check (no check, checking rule).

In this configuration item, you can define task list usages to assign routing to various work areas. You can create several task lists with various usages for the production of a material. In work orders, you can assign order types to usages. The system uses the usage in an order for automatic task list selection.

You can specify that a routing is to be used only for plant maintenance or for goods receipt.

Define task list usages.

You use this configuration item to define a collection of default values for task list headers and operations.

You can minimize the maintenance of task list data as follows:

• Data from the material master is proposed
• Data from the work center can be referenced or copied
• Data from the profile is proposed

You can enter a profile in routing maintenance. The values from this profile are proposed when you create a new routing or routing object, such as a header or an operation. This data can either be saved or overwritten.

The profile contains default values for the status or for the operation increment.

Note

The values you maintained in the material master or the work center will be proposed before any values from the profile.

1. Determine the default values that can reduce the amount of maintenance work in your company.

2. If necessary, define several profiles.

3. Maintain the default values for routing maintenance.

You use this configuration item to create layouts for the single screen entry of confirmations. You do this by defining the confirmation profile for single screen entry of time ticket confirmations. You can define the layout of the entry screen. When you do this, you define which input and output fields are displayed and in which order. These definitions are saved in the profile.

• Standard Profile

  With the Standard Prof. indicator, you can define that the profile is to be used as the standard profile. Only one profile each can be defined as standard profile for single screen entry.

• Area Selection
  • In the header area you can define which data is to identify the operation or phase to be confirmed. Here, for example, you can define whether only the confirmation number and/or order, sequence and operation/phase can be entered.
  • In the detail areas, you define which information can be entered for the operation/phase to be confirmed and in which order the fields in question are displayed. You can select up to seven detail areas, each containing one group of possible entry fields. Note that every input and output field can only be outputted once. When you save, the system automatically checks whether this rule has been adhered to. To carry out this check beforehand, choose the Check area selection button.
  • Titles can be assigned to the detail areas, which are reproduced on the buttons above the corresponding area. You can use these buttons to open and close the areas. 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 is first called up.
  • You can display a preview of the individual area and also of the entire entry screen. To do this, choose the corresponding button (Header area preview, Detail area preview, List screen preview)
• Defaults
  • Confirmation function

    You define whether a partial confirmation, final confirmation, or final confirmation with posting of open reservations is to be proposed.

  • Default value
    • You can define the time of default determination for quantities and/or activities:
      • No proposal
      • Immediate proposal
      • Proposal when saving
    • For default determination:
      • The quantity that is still to be confirmed is calculated
      • The activities are calculated in proportion to the quantities

For the activities, you can define 6 texts that are displayed during confirmation entry. These texts are overwritten with the texts from the standard value key in the work center after you have chosen Enter. If you want to prevent this from happening, set the indicator Fix text. You can hide activities for which you do not want to enter a confirmation by setting the indicator Hidden.

Note

The texts entered for the buttons in the detail area and for the activities are saved in the logon language.

You use this configuration item to define the parameters for scheduling process orders per plant, order type, and production supervisor. This comprises maintaining detailed scheduling, date adjustment when dates are exceeded, scheduling control for detailed scheduling, and reduction.

• In Detailed Scheduling you specify:
  • How production dates are determined
  • Whether capacity requirements are generated
• In Adjust Scheduling you specify whether and how basic dates are adjusted to the production dates (for example, when deadlines are exceeded) and where the dates for the dependent requirements are meant to be.
• In Scheduling control for detailed scheduling you specify the control parameters for detailed scheduling, among others
  • Scheduling Type

    Here you specify the scheduling direction and whether scheduling is to be carried out to specific points in time. You can also specify that a scheduling run is only to be used to generate capacity requirements.

  • Start Date in the Past

    Here you specify how many days an order may lie in the past before today's scheduling is automatically triggered.

  • Automatic Scheduling

    Here you can specify whether scheduling is automatically executed on saving if changes relevant to scheduling have occurred.

  • Automatic Log

    Here you specify whether the log is automatically displayed after scheduling.

  • Scheduling with Breaks

    Here you specify that the times of a break are to be taken into account.

  • From Production Dates

    Here you specify that when creating or changing an order the user must enter the scheduled dates (production dates) instead of the basic dates.

  • Shift Order

    Here you specify whether the order can be moved if partially confirmed operations exist.

  • Latest Staging Date

    Here you specify where the required date of a component is to be in relation to the operation.

• In Reduction you specify
  • Up to what maximum reduction level the reduction takes place
  • To what percent the floats before and after production in every reduction level are to be reduced

Define the scheduling parameters for process orders.

You use this configuration item to create production scheduling profiles for specific plants. The production scheduling profile is adopted in the process order at the time the order is opened.

In a production scheduling profile, you can:

• Specify that certain business transactions or processes are to be carried out in parallel in a process order
  • Order release at the time the order is created
  • Scheduling of the order when it is released
• Specify whether only partial quantities are to be confirmed at the time of an availability check
• Make various specifications in the area of batch management:
  • Automatic batch creation when an order is opened
  • Branching to batch classification when a batch is changed
  • Extended batch classification via Customer Function Call
• Specify settings regarding transport:
  • Specify that only transport requirements are to be created if transport requirements can be generated for all the components of the operation
  • Specify that either the committed quantities or the required quantities are to be taken into account when transport requirements are generated
  • Specify that the creation of transport requirements is to take place automatically
• Specify that in the case of the confirmation:
  • No short quantities are to be updated
  • No excess quantities are to be updated
• Specify which order type is to be suggested depending on the business process

You can assign a production scheduling profile to a:

• Material (Work Scheduling screen in material master)
  Note

  The assignment to a material takes higher priority.
• Production supervisor

1. Create the necessary production scheduling profiles.

2. Assign the profiles to the appropriate materials or production supervisors.

You use this configuration item to assign several capacities belonging to different categories to one work center.

Capacity categories can be, for example:

• Machine
• Labor
• Setup crew
• Emissions

You must maintain the available capacity for every capacity category (for example, shift start, shift end, calendar, and so on). You can maintain default values for this data per plant and capacity category.

Define which capacity categories are to be available.

You use this configuration item to specify the tasks lists in which a work center may be used. You can, for example, categorize work centers into maintenance work centers or inspection work centers according to their relevance and their usage in maintenance plans or inspection plans. You can also allow multiple, cross-application uses in any combination.

1. Define the usage key.

2. Assign the task list type to the usage key.

You use this configuration item to determine a person or group of people responsible for maintaining the master data in certain work centers. These employees are not responsible for planning tasks but only for the maintenance of the work center parameters.

Define the people responsible for your work centers.

You use this configuration item to specify which data is contained in an operation that is automatically created during order creation. Within order creation, you can determine that an operation is created automatically if no routing 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 key

  The control key specifies how an operation is processed (for example, whether it is scheduled, costed, and so on)

• Operation number
• Operation short text
• Material group (only for external processing)
• Work center where the operation is carried out

Specify the data for operations automatically created by the system.