Configuring Manufacturing Master Data

When you create a new routing, you can assign a profile with default values, as shown in the previous figure.  

As the two previous figures show, you can preset the following default values at header and operation level, among others:

• Usage
• Overall Status
• Operation number increment
• Base Quantity

The profiles with default values for routings are created and maintained in the configuration activity, Define Profiles with Default Values. 

When you open the configuration activity, you first see an overview of the profiles that have already been created, as shown in the previous figure. You can create new entries or display or change the details of already existing entries.

In the detail view of an entry you can define the following default values:

• Header:
  • Predefined plant:

    This plant is proposed, for example, when you create a new routing within a routing group.

  • Usage:

    This key specifies the areas in which the routing can be used, for example, in production or engineering.

  • Status:

    This key indicates the processing status of a routing. For example, you can indicate whether the routing is still in the creation phase or has already been released.

  • Task List Unit:

    Normally the unit of measure in the material master is used in routing. If you have not maintained a unit of measure in the material master, the unit from the profile is proposed.

• Operation:
  • Operation increment:

    The increment is used when operations are automatically numbered.

  • Base Quantity:

    The Base quantity is the quantity of the material to be produced to which the standard values of the operation refer.

  • Numerator / Denominator:

    Numerator / denominator of the quotient that specifies the ratio of the unit of measure to the base unit of measure.

    To convert a quantity, whose unit of measure is not the same as the base unit of measure, into the base unit of measure, the system requires a quotient:

    Quantity (in alternative unit of measure) = quotient * quantity (in base unit of measure)

  • Currency:

    Currency for calculating operation-related costs.

  • Standard Value Determination Type:

    This key controls how the standard values are calculated.

  • Standard Value Key:

    A standard value key is defining to six standard values. The system uses standard values as parameters with origin standard value in formulas to calculate durations, capacity requirements, and costs.

    Note

    Standard value keys are defined and maintained in the configuration activity, Define Standard Value Key. This is explained later in this lesson.

When you create a new master recipe, you can assign a profile with default values, as shown in the previous figure.  

As the previous figure shows, you can preset the following default values, among others:

• Operation and phase number increment
• Control Key

The profiles with default values for master recipes are created and maintained in the configuration activity, Define Master Recipe Profiles with Default Values. 

When you open the configuration activity, you first see an overview of the profiles that have already been created, as shown in the previous figure. You can create new entries or display or change the details of already existing entries.

In the detail view of an entry you can define the following default values:

• Control key:

  A control key defines, for example, whether an operation or phase is scheduled, whether capacity requirements are to be determined or whether the operation or phase is to be confirmed.

  Note

  Control keys are maintained in the configuration activity, Define Control Key. This is explained later in this lesson.
• Operation increment:

  The increment is used when operations and phases are automatically numbered.

• Relationship view:

  This key determines the perspective from which the relationships in the phases are displayed: From the perspective of predecessor, successor, predecessor & successor (mixed), or as created.

• Change rule:

  This key specifies which change procedure must be used for recipe editing.

You assign a planner group in the header data of a routing and a master recipe. This is helpful for the effective selection and maintenance of your routings and master recipes.  

Planner groups are created and maintained in the configuration activity Configure Planner Group. They are defined at plant level.

How operations and phases in production orders and process orders are processed from a business perspective is defined using control keys. A suitable control key must be assigned to each operation and phase in a routing and a master recipe. A control key defines, for example, whether an operation or phase is scheduled, whether capacity requirements are to be determined, or whether the operation or phase is to be confirmed. Control keys are maintained in the configuration activity, Define Control Key.

The previous figures show the operation overviews of a simple routing and a simple master recipe. A control key is assigned to each operation and each phase.

Control keys are maintained in the configuration activity, Define Control Key.

When you open the configuration activity, as shown in the previous figure, you first see an overview of all the entries that are already created. You can create new entries or display or change the details of already existing entries.

In the detail view of an entry, you find the following information and control settings:

• Scheduling:

  If you set this indicator, the operation or phase is scheduled.

• Determine capacity requirements:

  If you set this indicator, capacity requirements are determined when the operation or phase is scheduled.

• Inspection characteristics required:

  If you set this indicator, inspection characteristics are to be maintained for the operation or phase.

• Automatic goods receipt:

  If you set this indicator, a goods receipt for the production or process order is posted automatically when confirming the operation or phase.

• Rework:

  With this indicator, you specify that an operation or phase is designated for rework. If you set this indicator, you cannot set the Automatic Goods Receipt indicator, since the goods receipt for rework quantities must be posted manually.

• Costing:

  If you set this indicator, the operation or phase is taken into account in costing.

• Schedule external operations:

  This setting is only taken into account if the operation or phase is marked as externally processed in the control key in the field external processing. This indicator determines that the operation or phase can be scheduled using its standard values if it is externally processed. If the indicator is not set, then the operation or phase is scheduled using its planned delivery time when it is externally processed.

• Not relevant for MES:

  If you set this indicator, an external manufacturing execution system (MES) can interpret the operation or phase as not relevant for processing in MES.

• External processing:

  With this indicator, you can specify whether an operation or phase is internally or externally processed or both.

• Confirmations:

  You set this indicator to specify whether and how an operation or phase is confirmed.

Standard values are used to define the planned activities for the operations of routings and the phases of master recipes. The standard values available in an operation and a phase are defined by the assigned work center or the assigned resource. A work center or resource is assigned a standard value key to which the respective standard values are assigned.

The previous figures show the following examples:

In the first example, the work center WC1-001 is assigned to the operation 0010 of the routing for the production of the material BIKE-001. The standard value key, SAP1, with the standard values, 'Setup', 'Machine', and 'Labor' is assigned to the work center. For these standard values, the following planned activities are defined in the operation: 

• Setup: 15 minutes
• Machine: 3 minutes
• Labor: 3 minutes

In the second example, the resource RES-SILO is assigned to phase 0020 of the master recipe for paint production. The standard value key, YBP1, with the standard values 'Machine' and 'Labor' are assigned to the resource. For these standard values, the following planned activities are defined in the phase:  

• Machine: 5 hours
• Labor: 5 hours

Standard value keys are defined and maintained in the configuration activity, Define Standard Value Key.

When you open the configuration activity, you first find an overview of all standard value keys that are already created, as shown in the previous figure. You can create new standard value keys or display or change the details of already existing standard value keys.

Up to six standard values can be assigned in the detailed view of a standard value key. A standard value is defined by a parameter of origin two. The parameters are defined and maintained in the configuration activity, Define Parameters.

The previous figure shows the definition of the standard value key, SAP1 Normal production, which is assigned to our example work center, WC1-001. The parameters, SAP_01 Setup, SAP_02 Machine and SAP_03 Labor are assigned.

You use the parameters, for example, when defining standard value keys and the formulas for capacity planning, scheduling, calculation, and PRT management. Parameters are defined and maintained in the configuration activity, Define parameters.

When you open the configuration activity, you first find an overview of all parameters that are already created, as shown in the previous figure. You can create new parameters or display or change the details of already existing parameters.

In the Detail view, you define the description and further attributes of a parameter. Which attributes you have to maintain depends on the origin of the parameter.

In the origin, the assignment of a parameter to a data field is defined. For example, the parameter, SAP_02, has the origin Standard Value, as shown in the previous figure. Therefore, it receives its value from the standard value to which it is assigned.

Parameters can have the following origins:

• Standard value
• Work center or resource constant:

  In a work center or resource, you can assign a value and a unit to up to six work center constants.

• General formula constants:

  You can assign a value and a unit to general formula constants.

• General operation value:

  The parameter is assigned to a data field of an operation or a phase, for example, operation quantity or the base quantity. In this case, you must explicitly enter the Field name, for example BMSCH for the base quantity.

• Value from PRT allocation:

  You assign the parameter to a field in the PRT allocation, for instance the PRT quantity.

• PRT constant:

  In the PRT master record, you assign a fixed value to the parameter. This parameter can only be used for PRT management.

Work centers and resources contain data that is essential for capacity planning.

In the Capacity tab, a work center or resource can be assigned several capacity categories, that is, availabilities of certain activities over time. The capacity categories are defined in the configuration activity, Define Capacity Category. The available capacities are defined per capacity category in the work centers and resources.

Furthermore, formulas for calculating the capacity requirements of operations or phases can be assigned to each capacity category. For work centers of routings, formulas can be assigned for the calculation of the capacity requirements of the operation segments setup, processing, and teardown. For resources of master recipes, a formula can be assigned for the calculation of the capacity requirement of a phase. The formulas are defined in the configuration activity, Define Formulas for Work Centers. They contain parameters that are defined in the configuration activity, Define Parameters.

The previous two figures show the following examples:

In the first example, capacity categories 001, Machine, and 002, Person, are assigned to the work center, WC1-001. For each capacity category, an available capacity is defined in which, for example, the working and break times are defined. Formulas are assigned for each capacity category: Formula SAP005 for calculating the capacity requirement for setup and formula SAP006 for calculating the capacity requirement for processing. In our example, no formula is defined for calculating the capacity requirements for teardown. The formulas can be displayed in the work center. As an example, the formula SAP006 displays.

In the second example, capacity categories 001, Machine, and 002 Person are assigned to the resource RES-SILO. For each capacity category, formula YBPI01 for calculating the capacity requirement of a phase is assigned. The formula is displayed. 

Capacity categories are defined in the configuration activity, Define Capacity Category.

In our example, the capacity categories 001, Machine and 002, Person are defined, as shown in the previous figure.

Formulas for work centers and resources are defined in the configuration activity, Define Formulas for Work Centers.

When you open the configuration activity, you first find an overview of all formulas that are already created, as shown in the previous figure. You can create new entries or display or change the formulas that are assigned to an entry.

In the detail view of an entry, you define the formulas using parameters that you define in the configuration activity, Define Parameters.

The formula parameters can be linked mathematically using the following operators:

• addition: +
• subtraction: -
• multiplication : *
• division: /

By setting the corresponding indicators, you can define for which applications the formula can be used:

• Calculation (Costing)
• Capacity Planning
• PRT Management
• Scheduling

The principle of calculating capacity requirements for an operation is explained in the previous figure. Formulas for calculating the capacity requirements of the setup, processing, and teardown time elements can be assigned in the work center for each capacity category. The parameters of the formulas are evaluated with values from the operation of the order and the formulas are executed. The control key of the operation must enable capacity requirements to be calculated.

Work centers and resources contain data that is essential for scheduling.

In the Scheduling tab, one of the assigned capacity categories must be specified as the scheduling basis.

Furthermore, formulas for calculating the durations of operations or phases are to be assigned. For work centers of routings, formulas can be assigned for the calculation of the durations of the operation segments setup, processing, and teardown. For resources of master recipes, a formula can be assigned for the calculation of the phase duration. As already explained, the formulas are defined in the configuration activity, Define Formulas for Work Centers. They contain parameters that are defined in the configuration activity, Define Parameters.

The previous two figures show the following examples.

In the first example, for the work center WC1-001, capacity category 001, Machine, is defined as a scheduling basis. The following formulas are assigned: Formula SAP001 for calculating the duration of the setup time and formula SAP002 for calculating the duration of the processing time. In our example, no formula is defined for calculating the duration of the teardown time. 

In the second example for resource RES-SILO, capacity category 001, Machine, is defined as a scheduling basis. Formula YBPI01 for calculating the phase duration is assigned.

The principle of calculating the durations of an operation is explained in the previous figure. Formulas for calculating the durations of the setup, processing, and teardown time elements are assigned in the work center. The parameters of the formulas are evaluated with values from the operation of the order and the formulas are executed. One of the assigned capacity categories must be specified as the scheduling basis. The control key of the operation must enable scheduling.

You assign a person responsible in the basic data of a work center and a resource. This is helpful for the effective selection and maintenance of your work centers and resources. 

You also specify the usage of a work center or a resource. The usage controls in which types of task lists you can use the work center or resource. Task list types include, for example, routings, master recipes, and inspection plans.

The previous two figures show the following examples:

• In the first example, person responsible 002 and the usage 009 All task list types are assigned to work center WC1-001.

• In the second example, the person responsible 001 and the usage 008 Master Recipe are assigned to resource RES-SILO.

Responsible persons are maintained in the Determine Person Responsible configuration activity. They are defined at plant level.

The usages of work centers and resources are maintained in the Define Task List Usage for Work Centers configuration activity.

When you open the configuration activity, you first find an overview of all usages that have already been created, as shown in the previous figure. You can create new entries or display or change the task list types that are assigned to an entry.

You can assign several task list types to each usage. For example, the task list type 2 Master Recipe is assigned to Usage 008, as shown in the previous figure. Our example resource RES-SILO mentioned before can therefore only be used in master recipes.

For production versions, a consistency check is available which can be used to check the consistency between the production version and the assigned plan and BOM. Inconsistencies can be displayed as warnings or errors.

In the example shown in the previous figure, production version 0001 of material BIKE-001 is checked in the Production Version: Mass Processing app. The check result shows that there is an inconsistency regarding the lot size range of the assigned routing. 

When consistency checks are performed on production versions, the system chooses the checks to be performed and the issue severity to be reported based on settings for the issue types in the configuration activity, Define Inconsistency Checks for Production Versions.

Findings of any issue type can be reported as errors or warnings by setting the appropriate issue severity for that issue type.

The issue severity can be set to Do Not Check if any specific issue type is not evaluated.

In the previous figure, for example, the issue type Inconsistency in Lot Size between tasklist and production version is assigned the issue severity Error.

Production versions can be created automatically based on proposals using the Process Production Versions or Schedule Mass Creation of Production Version apps.

The two previous figures show the following example: In the Process Production Versions app, a production version is proposed for the material BIKE-001.

The proposals can be checked by navigating to the Production Version Proposal detail view. Finally, the new production version can be created or rejected.

The proposals for the automatic creation of production versions are based on the configuration activity, Define Rules for Production Version Proposals.

When you call up the configuration activity, you find an overview of the Production Version Proposal Automation Rules that are already created, as shown in the previous figure. You can maintain an existing rule or create a new rule.

A rule is created with reference to the following data: material group, plant, MRP controller, and task list type.

The following priorities apply to the selection of a rule for the automatic creation of a production version:

• The specific values selected for material group, plant, MRP controller, and task list type takes priority over the generic values.
• The specific selection made for material group takes precedence over plant and MRP controller and task list type.
• The specific selection made for plant and MRP controller takes precedence over task list type.

The following still applies:

• A specific selection for MRP controller can be made only if a specific value for plant has been maintained.
• Generic values can be set by selecting, respectively, the fields Relevant for All Material Groups, Relevant for All Plants, Relevant for All MRP Controllers.

The previous figure shows the detailed settings of a rule.

Setting specific values for the field, Issuing Storage Location, Receiving Storage Location, and Warehouse Number is possible only if a specific plant has been maintained.