Defining Trackable Tools and Assigning them to Shop Floor Routings

Objective

After completing this lesson, you will be able to explain tool tracking by preparing production tools, assigning tools to operation activities, and managing automatic claiming/registration.

Tool Usage Tracking

In classical and PEO-specific version-controlled routings, you can attach Production Tools and Resources (PRT) to operations or operation activities. It is intended to instruct the operator on the shop floor to use a specific tool when performing an operation activity. It is assumed that the tool is available at the required time of execution and that the operator actually made use of it. However, there is no control over whether this exact scenario happens.

SAP S/4HANA PEO enhances tool tracking by improving control over tool usage in production. Alongside standard PRT assignments to operation activities, it introduces two key concepts: tool claiming and registration.

Tool Claiming

Claiming a tool is like an exclusive reservation of a particular tool for a user, a work center, or an operation activity. No other object or person gets access to this tool as long as it is claimed. In addition, the claiming event also triggers a movement from the warehouse to the production location which is reflected in the status CLM Claimed.

Note

Transfer posting will only be done if BADI is implemented by a customer – otherwise, only the status change takes place.

Claiming can be performed manually in the Track Tool Usage app or it can be configured to take place automatically, triggered by an action handler assigned to the register action.

Tool Registration

Tool registration is the process of documenting the tool number that has been used in production. The registration is performed manually by the operator after starting an operation activity in the Perform Work app. If the registration is meant to be mandatory it can also be configured as an automatic event triggered by an action handler assigned to an action (for example, SAP_COMPLETE). In that case, it is even recommended to check and perform the claim as well automatically, even though the claiming and registration events are not mutually dependent.

The registered tool will be recorded for a serialized product (SFI@OA) or for an operation activity (OA). It becomes part of the as-built BOM and is captured in the production action log.

Tool Tracking Process

In order to implement the tool tracking process, the material and equipment master data for serialized tools has to be set up in a specific way before it is put on stock. Afterwards, it can be used by the production engineer as an attachment to an operation activity of a version-controlled shop floor routing. The production engineer may configure the PRT registration as mandatory or optional depending on business requirements. They can even enforce the registration and claim of tools by assignment of the corresponding action handler to specific operation activities.

High Level Process Flow for Tool Tracking

High level chart of Tool Tracking Process

Master Data Specialist

  • Define Tools
    • Creates a material of the PRT category with PRT usage relevant for PEO DFR
    • Sets the tool as registrable
    • Assigns a Serial Number Profile
  • Goods Movement
    • Goods receipt for the PRT material
    • Stock of material (serialized equipment) is available

Production Engineer

  • Shop Floor Routing
    • Creates a shop floor routing
    • Assigns the material PRP or equipment to OA on the PRT tab
    • Defines the material PRT or Equipment as registrable and claimable
    • Adds PRTs input into OA’s interactive work instructions
    • Assigns PRTs related action handlers to OA

Production Planner

  • MRP
    • Creates planned order
  • Planned Order Conversion
    • Converts planned orders to production orders

Production Supervisor

  • Manage Production Order
    • Release production order

Production Operator

  • Manage Tools
    • Claims an equipment in the Track Tool Usage app (for usage in order/operations/OAs, or user usage, or work center)
    • The equipment status changes from "In the warehouse" ESTO + Claimed
  • Perform Operation Activity
    • Starts an operation activity with the material or equipment PRTs assigned and gets a new view "PRT on the left side"
    • The equipment and its serial number is auto registered via the configuration action handler
    • Completed OA
    • Tool is unclaimed (either via action handler or manually by operator) and changes its status from "Claimed" and "In the warehouse" ESTO to ESTO

Production Supervisor

  • Production Action Log
    • Record tool registration action
    • Records tool unclaim action
  • Production Genealogy
    • Displays registered tool and its serial number

During production, the operator and supervisor use the Track Tool Usage and Perform Work apps in order to execute the claiming and registration events. All actions, whether performed manually or automatically, are recorded in the Production Action log and the Product Genealogy report for further reference.

Defining Trackable Tools

Trackable tools are like non-trackable tools based on material type PRT. They need to have a serial number profile assigned and on the PRT view in the material master, the PRT Usage must be defined as 009 (for PEO SFR) and the Registrable checkbox will be activated.

Screenshot of Material Type FHMI for Trackable Tools
Screenshot of PRT Usage 009 and Registrable Checkbox
Screenshot for Equipment View for Trackable Tool

For this instance, it is now possible to book a goods receipt using the MIGO transaction. Thereafter, the status of the equipment will change to ESTO UII, which means that it is put into the warehouse and the UII identifier is attached.

Screenshot of Equipment Status when Available in the Warehouse

Assignment of PRT to Operation Activity

The production engineer determines which tools are to be used at what operation activity. They define if the tool usage has to be registered during execution or not. By default, the Registrable flag is set when a tool is assigned to an operation activity (assuming the flag was set in material master), but that can be changed for any particular tool or operation activity.

Screenshot of PRT Assignment to Operation Activity with regstrable on/off highlighted

If needed, the production engineer assigns specific action handlers for tool management. Examples include auto registration of claimed tools, checking PRT registration, and auto unclaiming tools upon operation activity completion.

Screenshot of Action Handler for Automatic Registration

Inserting PRT to Work Instructions

Finally, the trackable tools need to be added to the work instruction of the corresponding operation activity to enable the operator to register the proper serial number of the tool during production execution.

Screenshot of Work Instructions for PRT Registration

Summary

  • Use tool tracking to manage tool claiming, registration, and status changes in production processes.
  • Define trackable tools with serial number profiles and registrable status for controlled usage and tracking.
  • Assign PRTs to operation activities; set registrable status and use action handlers for automated tool management.
  • Insert trackable tools into work instructions to enable operators to register serial numbers during execution.

Assign a Trackable Tool to an Operation Activity and Add to Work Instruction

Business Example

John is a production engineer at the low-volume A&D Company focusing on the final assembly of complex products. The Company would like to use tool tracking capabilities in order to ensure that the pre-assigned resources and tools are available and used during production execution. John is given the task to set up the master data for trackable tools in order to use them in production.

Release the Shop Floor Routing, Create a Production Version, and Approve Workflow Review Steps

Business Example

Eric is a production engineer in the low-volume A&D Company. He needs to review the shop floor routing to ensure that it is ready to be released. If he finds any inconsistencies, he can leverage workflow capabilities and reject the task. This resets the routing back to the previous step so that the identified issue(s) can be fixed. Once the routing has been finalized, he needs to release it, create a production version, and complete the routing workflow.