Exploring SAP Fiori Applications for Material Replenishment with Kanban – In-House Production (4B3)

• Maintain PIRs (F3445) SAP Fiori App
• Schedule MRP Runs (F1339) SAP Fiori App
• Manage Repetitive Manufacturing (MF50) SAP GUI App
• Set Kanban Container Status (F3717) SAP Fiori App
• Pick Components for Production Orders (CO27) SAP GUI App
• Confirm Production Operation (F3069) SAP Fiori App
• Confirm Repetitive Manufacturing (MFBF) SAP GUI App
• Reprocess Goods Movements (COGI) SAP GUI App

You can use the Maintain PIRs app to create and monitor planned independent requirements (PIRs) of materials in months or weeks. The information can be used to negotiate rates with your suppliers and, as a result, reduce costs. PIRs are used to procure or produce materials or components prior to receiving sales orders for materials. This information is particularly important if the lead times demanded by your customers are shorter than those to which your suppliers can commit.

The Maintain PIRs app helps you detect forecasting errors early in the process so you can produce or purchase sufficient quantities of material to cover future sales demands on-time. The forecast period indicator is defined in the material master.

Note

The Maintain PIRs app only shows results for the selected period indicator. The default view is set to monthly periods.

• Sort and filter the list of materials based on various filters such as reach, accuracy, plant, active version, or period indicator.
• Determine the reach of your PIRs and find materials with an insufficient reach.
• See how accurate your PIRs are for each period.
• Create additional PIR versions for each material.
• Change a PIR version to active or inactive.
• Mass maintain your PIRs - you can process materials either in months or weeks for up to 12 months or 52 weeks. You can also adjust the period within which you want to process the PIRs.
• Use Microsoft Excel files using the comma-separated value file format (.csv) to maintain PIRs.

During the MRP run, the system checks whether current material demand can be covered by current inventory and expected material receipts. In a regenerative MRP run, the system plans all materials irrespective of whether they have been changed since the last MRP run. In a net change MRP run, the system only includes materials that have been changed since the last planning run in the new planning run. If current demand is not covered, the system creates purchase requisitions.

You can use this app to create and schedule a job for executing your MRP runs. To automate the planning process, the MRP run has to be carried out on a regular basis so you can use this app to create a job that performs this task for you; reducing your workload by running this task smoothly in the background.

You can perform the following tasks if the role Production Planning - MRP Runs is assigned to your user:

• Create and schedule jobs for your MRP runs. You can define:
  • The description, start date, start time and recurrence of the MRP run.
  • Specific control parameters for the MRP run.
  • The planning scope of the MRP run.
• Monitor the jobs and display information on the status, planned start, end, and duration, for example. In the Job Details screen you can display a log with information on the planning run.
• Cancel the job.

The Manage Repetitive Manufacturing app is based on the SAP transaction MF50, classified in the Production Planning and Control module under the application component Repetitive Manufacturing. This app supports you in planning the production of materials on the production lines. Because repetitive manufacturing means mass-producing a material, detailed information about the production process and available components is maintained in the planning table. After material production is planned on the production lines, the planned orders are fixed. The Production Planner can make quantity changes in the Monitor Material Coverage - Net Segments app, if necessary.

• Search for a material
• Display the planning table
• Maintain planning table data

The Set Kanban Container Status app enables you to select or scan Kanban containers to trigger Kanban status changes. Typically, a container status is changed from Fullto Emptywhen the material in the container has been consumed and thus the replenishment process needs to be triggered. Manually setting an available Kanban to Emptycreates a JIT (Just in Time) call for the material to be replenished. Later, the container status will be set to Fullagain, the container quantity will be increased, and inventory will be moved to or received at the production supply area to be available for consumption in production processes afterwards.

You can use this app to select or scan Kanban containers to trigger Kanban status changes:

• Whenever a Kanban container is scanned or entered, it is first collected in the Entered list, the status change is not saved immediately. Before saving, this allows you to adjust the target status, and optionally set the batch (if the status is set to Fulland the material is batch managed), and adjust the quantity manually if needed (if the status is set to Full). For this, the containers can be selected one-by-one in the Entered list and then modified in the details area.
• If a container was scanned or entered accidentally, it can be removed from the Entered list by choosingRemove at the top of the details area.
• Once all containers are entered and manual changes are done, the status change is triggered by selectingSave. After this step, all saved containers are moved to the Saved list.
• Containers that are unknown to the system or that cannot be processed or saved are marked in red in the Entered list. The corresponding error message is shown both in the details area and in the error log.

There are three ways to enter the container identifier in the app:

• Enter the container identifier together with the next container status by using barcode reader devices configured in "keyboard wedge" mode. The Kanban card printout will per default show barcodes for setting the container to Fulland to Empty.
  • Please make sure that the cursor is in the top left input field (Enter Barcode) before the barcode reader device is used. Whenever the enter key is hit on any input field, the cursor is positioned again into the field for the barcode input to allow fast continuation of scanning even after manual adaptation of a container.
  • The barcode reader device needs to transmit the data in the following format: <container ID><next status code><enter>
  • The codes allowed for <next status code> can be taken from the following table:

  • Status Code	Description
    0	Next status is determined automatically from the status sequence
    1	Waiting
    2	Empty
    3	In Process
    4	In Transit
    5	Full
    6	In Use

• Another option is to enter container data through the value help on the input field, which provides ways of finding containers (for example, material, control cycle, production supply area). In this case, the target status is set to the next default status according to the status sequence. The target status can be manually changed as described previously.
• As a third option, the barcode (consisting of container ID and next status) can be entered manually in the format described previously. The entry "252", for example, sets the container 25 to Empty.

The Pick Components for Production Orders app is based on the SAP transaction CO27, classified in the Production Planning and Control module under the application component Production Orders. To withdraw materials for a production order, a manual goods issue can be used, or the picking list. The picking list enables you to view all components in a production order, maintain quantities, and post the goods movements.

• Search for production orders
• Display components for production orders
• Pick materials
• Post goods movements

The Confirm Production Operation app enables you to partially or completely confirm production operations. You can enter produced quantities, including scrap or rework, edit material movements, and specify durations for activities for the selected production operation.

Note

• You can only confirm operations with automatic trigger points but not operations with trigger points that require user interaction dialog boxes. To confirm such operations, use the Confirm Production Order Operation app.
• You can only confirm operations that belong to a standard sequence.

• Select a production order and a related production operation for processing.
• Record quantities for yield, scrap, or rework.
• Select a reason for variances from planned quantities.
• Get an overview of the backflushed components used for the production operation.
• Edit a material used in the production operation, for example the storage location or the quantity to be confirmed.
• Consume materials from various batches.
• Add and confirm unplanned materials.

  This app also supports goods movements to/from warehouse-managed storage locations with synchronous postings.

• Enter information on activities that have been defined for the work center, such as setup, machine, and labor times.
• Enter a note with additional information.
• Confirm the production operation partially or completely.

The Confirm Repetitive Manufacturing app is based on the SAP transaction MFBF, classified in the Production Planning and Control module under the application component Repetitive Manufacturing.

You use this app to conduct a backflush, which is an accounting method that records the costs associated with producing the good only after it has been produced, completed, or sold. Backflush costing/accounting is typically used by companies with short production cycles, commoditized products (not customized), and a low or constant inventory. The total costs of a production run are recorded all at once, at the end of the process. "Flushing" is to work backward, calculating the costs of products after they're sold, finished, or shipped.

In SAP S/4HANA, the backflush executes multiple activities in a single step, including finished product goods receipts, backflush of component materials, posting costs to cost collectors, and creation of material and journal entries.

If errors occur during backflushing (for example, insufficient warehouse stock available or important data, such as the issuing storage location), you can make corrections immediately in a component overview, where backlogs have been created for the complete requirement quantities of the components with errors. You may choose to process the backlogs later, however if negative stocks are allowed for the material in the storage location, the system can post negative stock quantities in some circumstances.

Conduct costing backflushes of production processes

The Reprocess Goods Movements app is based on the SAP transaction COGI, classified in the Production Planning and Control module under the application component Confirmations.

If errors occur during backflushing, you can make corrections immediately in this app, where backlogs have been created for the complete requirement quantities of the components with errors. After entering relevant search criteria, the system displays a list of all assemblies that correspond to the criteria and that have components to be postprocessed. This list is sorted by assemblies and production versions. You can review the generated list and correct missing material movements for planned orders that have already been processed.

• Search for missing material movements for previous backflush operations.
• Review the generated list data.
• Correct missing material movements for planned orders that have been processed.

• SAP Activate Roadmap Viewer

• SAP Best Practices for SAP S/4HANA Cloud, public edition

• SAP S/4HANA Cloud, public edition

• SAP Fiori Apps Reference Library

Note

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