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Abhijit Patil

This document provides an agenda and overview for an SAP end user training on the PP (Production Planning) module at a level 3. It discusses the training objectives, general information about the project and training schedule. It also covers the key PP concepts to be discussed like the organizational structure, list of processes, master data setup and long term planning. The training aims to help users understand and execute the PP processes and integration in SAP system.

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PP End User Training – SAP (Level – 3) 16th December - 2013
Page 2 An HCC Group companyCTM Training - ATEPresentation Title This presentation contains certain forward looking statements concerning future business prospects and profitability of Highbar Technologies Limited, which are subject to a number of risks and uncertainties and actual results could materially differ from those in such forward looking statements, important developments that could affect the company's operations include a downtrend in the information technology and infrastructure sectors, significant changes in political and economic environment in India, tax laws, labor relations, litigation etc. The company does not undertake to make any announcement in case any of these forward looking statements become materially incorrect in future or update any forward looking statements made from time to time by or on behalf of the company. All rights reserved. Copyright with Highbar Technologies Limited. Highbar is a trademark of Highbar Technologies Limited & other names, logos are trademarks of their respective owners. DISCLAIMER
Page 3 An HCC Group companyCTM Training - ATE Agenda  Objective  General Information  PP SAP Org. Structure  List of Processes  Process  Sub Processes  Key Terms & Concepts  Process flow with steps & Reports  Scenarios in Process  Highlights of process  Process Change  SAP T-codes & Master data to be used  DMS documents to be attached  Exercise  Assessment Questionnaire
Page 4 An HCC Group companyCTM Training - ATE Objective • Should be able to execute the Steps of process in the system • Understand end to end process with integration with Processes • Understand the process integration with other systems • Understand the validations & controls in system.
Page 5 An HCC Group companyCTM Training - ATE Agenda  Objective  General Information  PP SAP Org. Structure  List of Processes  Process  Sub Processes  Key Terms & Concepts  Process flow with steps & Reports  Scenarios in Process  Highlights of process  Process Change  SAP T-codes & Master data to be used  DMS documents to be attached  Exercise  Assessment Questionnaire
Page 6 An HCC Group companyCTM Training - ATE General Information • Current Stage of the project • Landscape details for testing • Other information • Schedule of Training
Page 7 An HCC Group companyCTM Training - ATE General Inforn.– Road Map Of ATE SAP Implementation Project Preparation Business Blueprint Realization Final Preparation Go-live & Support Training-Level1 Workshop System design BPD System handing over On going support Prepare Project Plan Receive hardware Receive software Mobilize project team ‘Business Projects’ scope AS-IS Study/Clarification 1 2 3 4 5 O n g o i n g k n o w l e g d e t r a n s f e r b e t w e e n H I G H B A R a n d A T E C o r e t e a m Enabled project Team System understanding & Gap identification Understanding and concept s Buy In Documentation and end user comfort Ongoing support and continuous improvement End user training Finalize cutover data Finalize master data Developments Internal System testing – SIT - 1 CTM Training 18/11/2012 09/02/2013 08/05/2013 05/07/2013 06/07/2013 Stabilization & BI- BO Impl. 6 System Config 18/11/2012 10/03/2013 30/11/2013 31/12/2013 09/01/2014 Completed In process Planned date Revised Date LEGEND 16.12.2013 UAT
Page 8 An HCC Group companyCTM Training - ATE Stores Unrestricted stock at Storage Location General Information – Landscape details for Testing Contractor Client No 100 Configuration ----------------------- Client No 120/150 ABAP development Development Server Client No 200 CTM Training & SIT - Testing ----------------------- Client No 210 End User Quality Server Client No 300 Production Server
Page 9 An HCC Group companyCTM Training - ATE General Information – Other • Attend the full sessions of the training • Please make this sessions interactive • Carry out the testing by the way of exercises given in training • Appraise process owners about change processes if required. • Practice in system by executing the transaction in system post training • We should discourage the discussions around the process mapped in system • Process observations if any shall be recorded separately for clarification later
Page 10 An HCC Group companyCTM Training - ATE General Information – Schedule of Training
Page 11 An HCC Group companyCTM Training - ATE Agenda  Objective  General Information  PP SAP Org. Structure  List of Processes  Process  Sub Processes  Key Terms & Concepts  Process flow with steps & Reports  Scenarios in Process  Highlights of process  Process Change  SAP T-codes & Master data to be used  DMS documents to be attached  Exercise  Assessment Questionnaire
Page 12 An HCC Group companyCTM Training - ATE PP Organization Structure
Page 13 An HCC Group companyCTM Training - ATE PP Organization Structure - Plant
Page 14 An HCC Group companyCTM Training - ATE PP Organization Structure – Storage Location
Page 15 An HCC Group companyCTM Training - ATE Organizational Structure - Plant
Page 16 An HCC Group companyCTM Training - ATE Organizational Structure - Plant
Page 17 An HCC Group companyCTM Training - ATE Organizational Structure – Storage Location
Page 18 An HCC Group companyCTM Training - ATE Organizational Structure – Storage Location
Page 19 An HCC Group companyCTM Training - ATE Organizational Structure – Storage Location
Page 20 An HCC Group companyCTM Training - ATE Organizational Structure – Storage Location
Page 21 An HCC Group companyCTM Training - ATE Agenda  Objective  General Information  PP SAP Org. Structure  List of Processes  Process  Sub Processes  Key Terms & Concepts  Process flow with steps & Reports  Scenarios in Process  Highlights of process  Process Change  SAP T-codes & Master data to be used  DMS documents to be attached  Exercise  Assessment Questionnaire
Page 22 An HCC Group companyCTM Training - ATE  PP Master Data  Long Term Planning ( Block,Interlock,Kerbstone,Crusher)  Make To Stock production planning & execution (Block,Interlock,Kerbstone,Crusher)  Make To Order production planning & execution – Sales Order MRP ( Pre-casting ) List of Processes
Page 23 An HCC Group companyCTM Training - ATE Agenda  Objective  General Information  PP SAP Org. Structure  List of Processes  Process - PP Master Data  Sub Processes  Key Terms & Concepts  Process flow with steps & Reports  Scenarios in Process  Highlights of process  Process Change  SAP T-codes & Master data to be used  DMS documents to be attached  Exercise  Assessment Questionnaire
Page 24 An HCC Group companyCTM Training - ATE PP Master Data – Sub Processes Production Planning & Control – Master Data  Maintain Bill Of Material  Maintain Work center  Maintain Routing Interdepartmental – Master Data  Activity Master  Cost Center
Page 25 An HCC Group companyCTM Training - ATE Agenda  Objective  General Information  PP SAP Org. Structure  List of Processes  Process - PP Master Data  Sub Processes  Key Terms & Concepts  Process flow with steps & Reports  Scenarios in Process  Highlights of process  Process Change  SAP T-codes & Master data to be used  DMS documents to be attached  Exercise  Assessment Questionnaire
Page 26 An HCC Group companyCTM Training - ATE PP Master Data – Key Terms & Concepts Material Master: • Material Master contains all the information, for all the material‘s, that company Procures, Produces, Stores and Sales. • Material Type (Similar Basic Attributes) - Raw Material (ZRAW) and FG (ZFIN). • Production Area related Information – Basic Data1, MRP1, MRP2, MRP3, MRP4 & Work Scheduling
Page 27 An HCC Group companyCTM Training - ATE PP Master Data – Key Terms & Concepts Bill Of Material: • The Bill Of Material is a complete formally structured list of the components that make up a product. • Different BOM can be used – Company Usage Area wise e.g. Costing, Production etc. • BOM Header: Base Quantity, Active/Inactive Status • BOM Item Details: Material No, Quantity, UOM, Item Category, Production plant. • BOM Data is used by activities MRP, Work Scheduling, Procurement, Product Costing. • Multi-Level Explosion: MRP, Product Cost and Production Order
Page 28 An HCC Group companyCTM Training - ATE PP Master Data – Key Terms & Concepts Work Center: • Work center is the place where an operation or activity is carried out within a plant • Work center: Represents as general as geographical location or as specific as a particular M/C/Production Line within a department or Person or Group of Persons performing a job. • Based on Usage Selection: Decides different Task Lists e.g. Routing, Rate Routing & Insp Plan • Work Center: SAP Plant Level • Work Center View: Basic data, Default values, Capacities, Scheduling and Costing
Page 29 An HCC Group companyCTM Training - ATE PP Master Data – Key Terms & Concepts Routing: • A routing contains the operations to be performed, their sequence and the various work centers involved to manufacture an item. • Routing: Standard Values (Times) for activities such as setup and processing. • Control Key for Internal or External Operations • Material Operation Components Assignment • Production resources / tools. • Inspection Characteristics (Inspection Specification)
Page 30 An HCC Group companyCTM Training - ATE Agenda  Objective  General Information  PP SAP Org. Structure  List of Processes  Process - PP Master Data  Sub Processes  Key Terms & Concepts  Process flow with steps & Reports  Scenarios in Process  Highlights of process  Process Change  SAP T-codes & Master data to be used  DMS documents to be attached  Exercise  Assessment Questionnaire
Page 31 An HCC Group companyCTM Training - ATE PP Master Data – Process Flow
Page 32 An HCC Group companyCTM Training - ATE PP Master Data - Process Flow
Page 33 An HCC Group companyCTM Training - ATE Agenda  Objective  General Information  PP SAP Org. Structure  List of Processes  Process - PP Master Data  Sub Processes  Key Terms & Concepts  Process flow with steps & Reports  Scenarios in Process  Highlights of process  Process Change  SAP T-codes & Master data to be used  DMS documents to be attached  Exercise  Assessment Questionnaire
Page 34 An HCC Group companyCTM Training - ATE PP Master Data - Scenarios Bill Of Material (BOM): • Standard Bill Of Material Sales Order Bill Of Material (BOM): • Sales Order BOM Work center • Work Center Routing • Standard Routing
Page 35 An HCC Group companyCTM Training - ATE Agenda  Objective  General Information  PP SAP Org. Structure  List of Processes  Process - PP Master Data  Sub Processes  Key Terms & Concepts  Process flow with steps & Reports  Scenarios in Process  Highlights of process  Process Change  SAP T-codes & Master data to be used  DMS documents to be attached  Exercise  Assessment Questionnaire
Page 36 An HCC Group companyCTM Training - ATE PP Master Data - Highlights Material Master: Material Types: ZRAW, ZFIN Price Control ZRAW: ‘V’ Moving Average Price Price Control ZFIN: ‘S’ Standard Price Material BOM: Material BOM Usage: 1 i.e. Production
Page 37 An HCC Group companyCTM Training - ATE PP Master Data - Highlights Sales Order BOM: Material BOM Usage: 3 i.e. Universal Work center: Work Center Category: 0001 i.e. Machine Routing: Task List Type: N i.e. Routing
Page 38 An HCC Group companyCTM Training - ATE Agenda  Objective  General Information  PP SAP Org. Structure  List of Processes  Process - PP Master Data  Sub Processes  Key Terms & Concepts  Process flow with steps & Reports  Scenarios in Process  Highlights of process  Process Change  SAP T-codes & Master data to be used  DMS documents to be attached  Exercise  Assessment Questionnaire
Page 39 An HCC Group companyCTM Training - ATE ‘MTS PP’ Master Data – Process Change 1. ‘ZFIN’ & ‘ZRAW’ Material Type Material Masters Maintenance with MRP Parameters 2. Cross Plant Planning: Special Procurement Key Maintenance in ‘ZFIN’ material type material master at receiving plant. 3. Joint Production: Co-Product setting and Cost Apportion Structure Maintenance in ‘ZFIN’ material type material master. 4. Work center creation with available capacity requirements for representing total Batching Plant Production Capacity. 5. Work center creation with cost center & activity master details 6. Routing creation with Planned Activity Values
Page 40 An HCC Group companyCTM Training - ATE ‘MTO PP’ Master Data – Process Change 1. ‘ZFIN’ & ‘ZRAW’ Material Type Material Masters Maintenance with MRP Parameters 2. ‘ZRAW’ Material Type Maintenance with Procurement details i.e. Individual and Collective. 3. Work center creation with available capacity requirements for representing total Batching Plant Production Capacity. 4. Work center creation with cost center & activity master details 5. Routing creation with Planned Activity Values
Page 41 An HCC Group companyCTM Training - ATE Agenda  Objective  General Information  PP SAP Org. Structure  List of Processes  Process - PP Master Data  Sub Processes  Key Terms & Concepts  Process flow with steps & Reports  Scenarios in Process  Highlights of process  Process Change  SAP T-codes & Master data to be used  DMS documents to be attached  Exercise  Assessment Questionnaire
Page 42 An HCC Group companyCTM Training - ATE PP Master Data - Transaction Codes
Page 43 An HCC Group companyCTM Training - ATE PP Master Data - Transaction Codes
Page 44 An HCC Group companyCTM Training - ATE PP Master Data - Transaction Codes
Page 45 An HCC Group companyCTM Training - ATE Agenda  Objective  General Information  PP SAP Org. Structure  List of Processes  Process – Long Term Planning  Sub Processes  Key Terms & Concepts  Process flow with steps & Reports  Scenarios in Process  Highlights of process  Process Change  SAP T-codes & Master data to be used  DMS documents to be attached  Exercise  Assessment Questionnaire
Page 46 An HCC Group companyCTM Training - ATE Long Term Planning – Key Terms & Concepts Long Term Planning: • Long term planning is used to analyse the production capacity load situation and material dependent requirements required for the production. Duration of LTP analysis can be from a one month to the years, subject to the realistic sales and production projections availability. Planning Scenario: • Planning scenario to determines the control parameters for long-term planning. This includes the plant where long-term planning is to be carried out, the planning period, and the independent requirements versions to be planned. Planning Scenario represents a particular division or a particular business area. Inactive Planned Independent Requirements Version : • LTP is carried out with inactive Planned Independent Requirements version. • Version ‘02’ is used for this purpose.
Page 47 An HCC Group companyCTM Training - ATE Long Term Planning – Key Terms & Concepts LTP MRP Run (MS02 or MSBT): • Long term planning MRP Run is carried out separately i.e. It is not part of operative planning. LTP MRP run can be carried out in foreground MS02 or background MSBT. Frequency of background MRP Run can be monthly or multiple months. LTP Evaluation (MS05 or MS04): • Long term planning MRP evaluation is carried out separately i.e. It is not part of operative planning. LTP evaluation is done once MRP Run takes place or it can be dynamically done as required. LTP Material Analysis (MCEC/MCEB): • Long term planning Material Analysis is possible only if material master is created with procurement type ‘F’.
Page 48 An HCC Group companyCTM Training - ATE Agenda  Objective  General Information  PP SAP Org. Structure  List of Processes  Process – Long Term Planning  Sub Processes  Key Terms & Concepts  Process flow with steps & Reports  Scenarios in Process  Highlights of process  Process Change  SAP T-codes & Master data to be used  DMS documents to be attached  Exercise  Assessment Questionnaire
Page 49 An HCC Group companyCTM Training - ATE Long Term Planning - Process Flow
Page 50 An HCC Group companyCTM Training - ATE Long Term Planning – Steps & Reports
Page 51 An HCC Group companyCTM Training - ATE Long Term Planning – Steps & Reports
Page 52 An HCC Group companyCTM Training - ATE Agenda  Objective  General Information  PP SAP Org. Structure  List of Processes  Process – Long Term Planning  Sub Processes  Key Terms & Concepts  Process flow with steps & Reports  Scenarios in Process  Highlights of process  Process Change  SAP T-codes & Master data to be used  DMS documents to be attached  Exercise  Assessment Questionnaire
Page 53 An HCC Group companyCTM Training - ATE Long Term Planning - Scenarios • LTP With Capacity Planning & Material Analysis
Page 54 An HCC Group companyCTM Training - ATE Agenda  Objective  General Information  PP SAP Org. Structure  List of Processes  Process – Long Term Planning  Sub Processes  Key Terms & Concepts  Process flow with steps & Reports  Scenarios in Process  Highlights of process  Process Change  SAP T-codes & Master data to be used  DMS documents to be attached  Exercise  Assessment Questionnaire
Page 55 An HCC Group companyCTM Training - ATE Long Term Planning - Highlights Current Stock: • LTP Considers current material stock during planning. Firm Receipts: • LTP Considers current firm receipts e.g. purchase orders, production orders from operative planning. • Firm Purchase Requisitions and firm planned orders are also considered during LTP planning Customer Receipts: • LTP Considers current customer orders from operative planning LTP Capacity Analysis (CM38): • LTP Capacity Analysis is done to analyze any future bottlenecks in terms of machine capacity availability.
Page 56 An HCC Group companyCTM Training - ATE Long Term Planning - Highlights LTP Material Analysis (MCEC & MCEB): • LTP Material Analysis is done for a particular material or for a particular material group. • As per material forecasting PO Value, Order Quantity and PO Price is possible to analyze.
Page 57 An HCC Group companyCTM Training - ATE Agenda  Objective  General Information  PP SAP Org. Structure  List of Processes  Process – Long Term Planning  Sub Processes  Key Terms & Concepts  Process flow with steps & Reports  Scenarios in Process  Highlights of process  Process Change  SAP T-codes & Master data to be used  DMS documents to be attached  Exercise  Assessment Questionnaire
Page 58 An HCC Group companyCTM Training - ATE Long Term Planning – Process Change 1. ‘ZFIN’ & ‘ZRAW’ Material Type Material Masters Maintenance with MRP Parameters 2. Cross Plant Planning: Special Procurement Key Maintenance in ‘ZFIN’ material type material master at receiving plant. 3. Work center creation with LTP Setting 4. Work center creation with available capacity requirements for representing total available Production Capacity. 5. Routing creation with Planned Activity Values – Capacity Planning 6. LTP – Planning Scenario Creation and Maintenance (MS31/MS32/MS3) 7. LTP – Inactive Version Planned Independent Creation (MD61)
Page 59 An HCC Group companyCTM Training - ATE Long Term Planning – Process Change 8. LTP – MRP Run (MS02) 9. LTP – Stock Requirement List (MS04) 10. LTP – MRP List (MS05) 11. LTP – Setting Purchase Info Records 12. LTP Material Analysis (MCEC/MCEB) 13. LTP Work center Capacity Planning (CM38) Operative Planning: 14. ‘ZRAW’ Material Type - LTP Dependent Requirements Copy to Operative Planning (MS66) 15. ‘ZFIN’ Material Type – LTP Planned Independent Requirements Copy to Operative Planning (MD61)
Page 60 An HCC Group companyCTM Training - ATE Agenda  Objective  General Information  PP SAP Org. Structure  List of Processes  Process – Long Term Planning  Sub Processes  Key Terms & Concepts  Process flow with steps & Reports  Scenarios in Process  Highlights of process  Process Change  SAP T-codes & Master data to be used  DMS documents to be attached  Exercise  Assessment Questionnaire
Page 61 An HCC Group companyCTM Training - ATE Long Term Planning - Transaction Codes
Page 62 An HCC Group companyCTM Training - ATE Long Term Planning – Master Data 1. Material Master – (Finish Good’s, Raw Materials) 2. Bill Of Material – Material BOM 3. Work Center 4. Routing
Page 63 An HCC Group companyCTM Training - ATE Agenda  Objective  General Information  PP SAP Org. Structure  List of Processes  Process – Make To Stock Planning & Execution  Sub Processes  Key Terms & Concepts  Process flow with steps & Reports  Scenarios in Process  Highlights of process  Process Change  SAP T-codes & Master data to be used  DMS documents to be attached  Exercise  Assessment Questionnaire
Page 64 An HCC Group companyCTM Training - ATE MTS Planning & Execution – Sub Processes 1. Make To Stock Planning & Execution with Planning Strategy 10 2. Make To Stock Planning & Execution with Joint Production ( Crusher )
Page 65 An HCC Group companyCTM Training - ATE Agenda  Objective  General Information  PP SAP Org. Structure  List of Processes  Process – Make To Stock Planning & Execution  Sub Processes  Key Terms & Concepts  Process flow with steps & Reports  Scenarios in Process  Highlights of process  Process Change  SAP T-codes & Master data to be used  DMS documents to be attached  Exercise  Assessment Questionnaire
Page 66 An HCC Group companyCTM Training - ATE MTS Planning & Execution – Key Terms & Concepts Make To Stock: • Make To Stock production environment produces good’s, products based on sales or production forecast. The production planning and execution activities takes place before receipt of firm customer orders. With this production environment it is possible to respond to customer orders fast with short lead time. Demand Management: • Demand Management consists of creation of planned independent requirements based on sales or production forecast. PIR are transferred to production planning & execution once MRP run takes place. MRP Run: • MRP i.e. Material Requirement Planning ensures material availability for in-house and external procurements. It transfers MTS requirements from demand management as well as a particular sales order requirements to production planning and execution. MRP Run also takes care of special procurement e.g. cross plant planning.
Page 67 An HCC Group companyCTM Training - ATE MTS Planning & Execution – key Terms & Concepts Cross Plant Planning: • Cross plant planning insures stock transfer reservations across production plant. During MRP Run at receiver plant, stock transfer reservations are created in sender plant. The stock transfer can be done from available stock or if shortage is there, then production is done against stock transfer reservations. Special procurement key 40, 41 and 42 is used for this purpose. Planned Order: • Planned Order is generated after MRP Run for in-house production as well as for external procurements. Capacity planning (finite scheduling) is done for in-house production on the basis of Planned order. Material availability is checked on the basis of planned order. Planned Orders are further converted to production orders for in-house production and to purchased orders for external procurements. • Planned Orders are changed or deleted during MRP run • Planned Order can be manually generated if MRP run is not applicable in process. • Firm planned orders are not changed or deleted during MRP run.
Page 68 An HCC Group companyCTM Training - ATE MTS Planning & Execution – Planned Order
Page 69 An HCC Group companyCTM Training - ATE MTS Planning & Execution – Key Terms & Concepts Joint Production (Crusher Only): • Joint Production SAP functionality is applicable when there is requirement to simultaneously produce multiple finish good’s materials. Total cost of production is distributed on all valuated finish good’s produced. Co-Product: • Co-Product are valuated materials produced along with main finish good. Total Cost of production is apportioned on co-product. Cost Apportion Structure: • Cost Apportion structure is created in main finish good material master. Total cost of production is apportioned on main production material and co-products as per this cost-apportion structure. Total of equivalence numbers for all FG materials in cost apportion structure is equal to 1000. Bill of material is the basis for defining cost-apportion structure.
Page 70 An HCC Group companyCTM Training - ATE MTS Planning & Execution – Co-Product
Page 71 An HCC Group companyCTM Training - ATE MTS Planning & Execution – Cost Apportion Structure
Page 72 An HCC Group companyCTM Training - ATE MTS Planning & Execution – Key Terms & Concepts Production Order: • Production order is created, to start the production of a material within a plant and to specify the material and quantity that will be produced. It decides the work location (capacity) that is used, which operations are required and the date on which production takes place. It also defines the Planned/Target production cost for the given production quantity. • Production Orders are considered as firm requirements. • Production order is released for production as per production plan. Production Order Type: • Production Order type decides control parameters for a particular production order. • Production Order types are configured in background. • Production Order Type defined at a particular division level. • Production Order type decides number range. Internal number range is followed at client level.
Page 73 An HCC Group companyCTM Training - ATE MTS Planning & Execution – Key Terms & Concepts Production Order System Status • Production Order system status is automatically updated once a particular business transaction is carried out. • It is not possible to modify any of the production order system status. Production Order User Status • Production Order user status is automatically updated once a particular business transaction is carried out. • It is possible to modify any of the production order user status. • User status is activated based on business transaction • Authorization is required to modify any of the production order user status.
Page 74 An HCC Group companyCTM Training - ATE MTS Planning & Execution – System Status/User Status
Page 75 An HCC Group companyCTM Training - ATE MTS Planning & Execution – Production Order
Page 76 An HCC Group companyCTM Training - ATE MTS Planning & Execution – Production Order Types
Page 77 An HCC Group companyCTM Training - ATE MTS Planning & Execution – Key Terms & Concepts Production Order Good’s Issue (GI): • Raw Materials are issued against production order. Actual material consumption is booked during Good’s Issue against production order as and when material is physically issued. • Production Order GI is integrated with Store and Account departments. • Raw Material can be handled in batches. Production Order GI Transactions: • MIGO: Store person issue Good’s Issue through normal MM transaction.
Page 78 An HCC Group companyCTM Training - ATE MTS Planning & Execution – Key Terms & Concepts Production Order Operation Confirmation: • Production Order Operation Confirmation i.e. Time Ticket Confirmation is done against production order. Machine and Manpower confirmation is done on daily basis. • Planned Production Overhead confirmation can be done on daily basis. Difference between plan and actual is posted at the end of the month once actual data is available by production order confirmation. • Yield, Scrap and Rework is booked during production execution. Scrap declared during production confirmation is not placed in stock.
Page 79 An HCC Group companyCTM Training - ATE MTS Planning & Execution – Production Ord. Confirmation
Page 80 An HCC Group companyCTM Training - ATE MTS Planning & Execution – Key Terms & Concepts Production Order Good’s Receipt (GR): • Production Order Good’s Receipt is done (TCode MIGO) to declare production and to place finish good’s in to stock. • Production Order GR is integrated with Store and Account departments. • Target Cost is updated in a production order for GR Quantity delivered. • With WIP batch (Sohar Factory only): GR Batches consumes preceding WIP batches. • Marble Tiles Line (TCode COWBHUWE): GR Posting with Handling Unit
Page 81 An HCC Group companyCTM Training - ATE MTS Planning & Execution – Material Document
Page 82 An HCC Group companyCTM Training - ATE MTS Planning & Execution – Key Terms & Concepts Production Order Locking: • Production Order is temporary restricted for transactions by locking production order. • Once decision is to continue production, production order is un-locked Production Order Technical Completion (TECO): • Production Order is logistically completed at the end of the production activities. • TECO system status is updated once production order is technically completed. • GI, Production Confirmation and GR is not possible once production order is technically completed. • ‘DAC’ (Disallow Cost) user status is updated once technical completion is done. Authorization is required to revert this user status.
Page 83 An HCC Group companyCTM Training - ATE MTS Planning & Execution – Key Terms & Concepts Production Order Settlement: • Technical completion is prerequisite to settle production order. • Production Order CO settlement is done at the end of period i.e. at the end of month by costing person. Production order balance becomes zero after production order settlement. Production Order Business Completion (CLSD): • Production Order business completion is done once production order is settled. Business completion is possible only if Production order balance becomes zero. • This activity is normally carried out by Costing person.
Page 84 An HCC Group companyCTM Training - ATE Agenda  Objective  General Information  PP SAP Org. Structure  List of Processes  Process – Make To Stock Planning & Execution  Sub Processes  Key Terms & Concepts  Process flow with steps & Reports  Scenarios in Process  Highlights of process  Process Change  SAP T-codes & Master data to be used  DMS documents to be attached  Exercise  Assessment Questionnaire
Page 85 An HCC Group companyCTM Training - ATE ATE Group – Process Matrix
Page 86 An HCC Group companyCTM Training - ATE MTS Planning & Execution – Process Flow
Page 87 An HCC Group companyCTM Training - ATE MTS Planning & Execution – Process Flow
Page 88 An HCC Group companyCTM Training - ATE MTS Planning & Execution – Steps & Reports
Page 89 An HCC Group companyCTM Training - ATE MTS Planning & Execution – Steps & Reports
Page 90 An HCC Group companyCTM Training - ATE MTS Planning & Execution – Steps & Reports
Page 91 An HCC Group companyCTM Training - ATE Agenda  Objective  General Information  PP SAP Org. Structure  List of Processes  Process – Make To Stock Planning & Execution  Sub Processes  Key Terms & Concepts  Process flow with steps & Reports  Scenarios in Process  Highlights of process  Process Change  SAP T-codes & Master data to be used  DMS documents to be attached  Exercise  Assessment Questionnaire
Page 92 An HCC Group companyCTM Training - ATE MTS Planning & Execution - Scenarios MTS Planning: A. MTS Planning • MTS Demand Management – Copy PIR from LTP Planning • MTS Manual Planned Order B. MTS Execution • MTS • MTS with Joint Production
Page 93 An HCC Group companyCTM Training - ATE Agenda  Objective  General Information  PP SAP Org. Structure  List of Processes  Process – Make To Stock Planning & Execution  Sub Processes  Key Terms & Concepts  Process flow with steps & Reports  Scenarios in Process  Highlights of process  Process Change  SAP T-codes & Master data to be used  DMS documents to be attached  Exercise  Assessment Questionnaire
Page 94 An HCC Group companyCTM Training - ATE MTS Planning & Execution - Highlights Planned Independent Creation: • Copy from LTP MRP Group: • MRP Group: Z004 - MTS (10) Manufacturing MRP Strategy: • MRP Strategy: 10
Page 95 An HCC Group companyCTM Training - ATE MTS Planning & Execution - Highlights Planned Order Profile: • Planned Order Profile: LA Production Order GI: • Production Order is Debited at the time of Good’s Issue Production Order Confirmation: • Production Order is Debited at the time of Production Operation Confirmation
Page 96 An HCC Group companyCTM Training - ATE MTS Planning & Execution - Highlights Production Order GR: • Production Order is Credited at the time of Production Good’s Receipt Production Order Variance: • Production Order variance is calculated on the basis of Target Cost. • Production Target Cost Vs. Actual Cost and Target Qty Vs. Actual Qty is analyzed • Difference between Target cost and Actual Cost is settled as per production order settlement rule, on production variance account and cost center.
Page 97 An HCC Group companyCTM Training - ATE Agenda  Objective  General Information  PP SAP Org. Structure  List of Processes  Process – Make To Stock Planning & Execution  Sub Processes  Key Terms & Concepts  Process flow with steps & Reports  Scenarios in Process  Highlights of process  Process Change  SAP T-codes & Master data to be used  DMS documents to be attached  Exercise  Assessment Questionnaire
Page 98 An HCC Group companyCTM Training - ATE MTS Planning & Execution – Process Change 1. Planned Dependent Requirement (MD61) - ‘ZFIN’ Material Type – LTP Planned Independent Requirements Copy to Operative Planning (MD61) 2. MRP Run (MD03/MDBT) 3. MRP List (MD05) 4. Stock Requirement List (MD04) 5. Planned Order Maintenance 6. Capacity Planning 7. Capacity Leveling 8. Planned Order Conversion to Production Order (Partial / Complete) 9. Production Order Capacity Planning 10. Production Order Capacity Evaluation 11. Production Order Release
Page 99 An HCC Group companyCTM Training - ATE MTS Planning & Execution – Process Change 12. Raw Material Availability Check – For a particular production order (lot). 13. Good’s Issue – Actual Qty for a particular production order (lot). 14. Activity Confirmation – Actual Machine/Manpower Hrs for a particular production order (lot). 15. Target Cost Run – ‘ZFIN’ material type. 16. Good’s Receipt – Good’s Receipt to declare Stock of Finish Good for a particular production order (lot). 17. Activity Confirmation – Actual Overheads for a particular production order (lot). 18. Production Order (lot) - Target Cost Vs. Actual Cost Analysis 19. Production Order Technical Completion 20. Production Order Settlement
Page 100 An HCC Group companyCTM Training - ATE MTS Planning & Execution – Process Change Operative Planning: 14. ‘ZRAW’ Material Type - LTP Dependent Requirements Copy to Operative Planning (MS66) 15. ‘ZRAW’ Material Type – Planning on the basis of Production Order Reservations.
Page 101 An HCC Group companyCTM Training - ATE Agenda  Objective  General Information  PP SAP Org. Structure  List of Processes  Process – Make To Stock Planning & Execution  Sub Processes  Key Terms & Concepts  Process flow with steps & Reports  Scenarios in Process  Highlights of process  Process Change  SAP T-codes & Master data to be used  DMS documents to be attached  Exercise  Assessment Questionnaire
Page 102 An HCC Group companyCTM Training - ATE MTS Planning & Execution - Transaction Codes
Page 103 An HCC Group companyCTM Training - ATE MTS Planning & Execution - Transaction Codes
Page 104 An HCC Group companyCTM Training - ATE MTS Planning & Execution - Transaction Codes
Page 105 An HCC Group companyCTM Training - ATE MTS Planning & Execution – Master Data 1. Material Master – (Finish Good’s, Raw Materials) 2. Bill Of Material – (Material BOM) 3. Work Center 4. Routing
Page 106 An HCC Group companyCTM Training - ATE Agenda  Objective  General Information  PP SAP Org. Structure  List of Processes  Process – Make To Order Planning & Execution  Sub Processes  Key Terms & Concepts  Process flow with steps & Reports  Scenarios in Process  Highlights of process  Process Change  SAP T-codes & Master data to be used  DMS documents to be attached  Exercise  Assessment Questionnaire
Page 107 An HCC Group companyCTM Training - ATE MTO Planning & Execution – Sub Processes 1. Make To Order Planning & Execution with Sales Order MRP
Page 108 An HCC Group companyCTM Training - ATE Agenda  Objective  General Information  PP SAP Org. Structure  List of Processes  Process – Make To Order Planning & Execution  Sub Processes  Key Terms & Concepts  Process flow with steps & Reports  Scenarios in Process  Highlights of process  Process Change  SAP T-codes & Master data to be used  DMS documents to be attached  Exercise  Assessment Questionnaire
Page 109 An HCC Group companyCTM Training - ATE MTO Planning & Execution – Key Terms & Concepts Make To Order: • Make To Order production environment produces good’s, products based on sales orders. The production planning and execution activities takes place only after receipt of firm customer orders. With this production environment it is possible to respond to minimize production inventory as well as this process caters effectively to deliver finish good’s with short shelf life e.g. Ready Mix Concrete etc. Sales Order: • Sales Order is created against contract based on customer delivery Schedule and delivery confirmation. System treats each schedule line as a separate procurement item. Production is done separately against each schedule line.
Page 110 An HCC Group companyCTM Training - ATE MTO Planning & Execution – Key Terms & Concepts Sales Order MRP Run: • MRP i.e. Material Requirement Planning ensures material availability for in-house and external procurements. It transfers customer requirements from a sales order requirements to production planning and execution. MRP Run also takes care of in-house production as well as external procurements. Planned Order: • Planned Order is generated after MRP Run for in-house production as well as for external procurements. Capacity planning (finite scheduling) is done for in-house production on the basis of Planned order. Material availability is checked on the basis of planned order. Planned Orders are further converted to production orders for in-house production and to purchased orders for external procurements. • Planned Orders are changed or deleted during MRP run • Planned Order can be manually generated if MRP run is not applicable in process. • Firm planned orders are not changed or deleted during MRP run.
Page 111 An HCC Group companyCTM Training - ATE MTO Planning & Execution – Planned Order
Page 112 An HCC Group companyCTM Training - ATE MTO Planning & Execution – Planned Order
Page 113 An HCC Group companyCTM Training - ATE MTO Planning & Execution – Key Terms & Concepts Production Order: • Production order is created, to start the production of a material within a plant and to specify the material and quantity that will be produced. It decides the work location (capacity) that is used, which operations are required and the date on which production takes place. It also defines the Planned/Target production cost for the given production quantity. • Production Orders are considered as firm requirements. • Production order is released for production as per production plan. Production Order Type: • Production Order type decides control parameters for a particular production order. • Production Order types are configured in background. • Production Order Type defined at a particular division level. • Production Order type decides number range. Internal number range is followed at client level.
Page 114 An HCC Group companyCTM Training - ATE MTO Planning & Execution – Key Terms & Concepts Production Order System Status • Production Order system status is automatically updated once a particular business transaction is carried out. • It is not possible to modify any of the production order system status. Production Order User Status • Production Order user status is automatically updated once a particular business transaction is carried out. • It is possible to modify any of the production order user status. • User status is activated based on business transaction • Authorization is required to modify any of the production order user status.
Page 115 An HCC Group companyCTM Training - ATE MTO Planning & Execution – System Status/User Status
Page 116 An HCC Group companyCTM Training - ATE MTO Planning & Execution – Production Order
Page 117 An HCC Group companyCTM Training - ATE MTO Planning & Execution – Production Order Types
Page 118 An HCC Group companyCTM Training - ATE MTO Planning & Execution – Key Terms & Concepts Production Order Good’s Issue (GI): • Raw Materials are issued against production order. Actual material consumption is booked during Good’s Issue against production order as and when material is physically issued. • Production Order GI is integrated with Store and Account departments. • System handles individual or collective procurements as per the setting in raw material, material master • Raw Material can be handled in batches. Production Order GI Transactions: 1. MIGO: Store person issue Good’s Issue through normal MM transaction. 2. CO11N (Sohar Marble Slab Line only): Material is issued through production order confirmation transaction. Here the input batches are linked with production order.
Page 119 An HCC Group companyCTM Training - ATE MTO Planning & Execution – Key Terms & Concepts Production Order Operation Confirmation: • Production Order Operation Confirmation i.e. Time Ticket Confirmation is done against production order. Machine and Manpower confirmation is done on daily basis. • Planned Production Overhead confirmation can be done on daily basis. Difference between plan and actual is posted at the end of the month once actual data is available by production order confirmation. • Yield, Scrap and Rework is booked during production execution. Scrap declared during production confirmation is not placed in stock.
Page 120 An HCC Group companyCTM Training - ATE MTO Planning & Execution – Production Ord. Confirmation
Page 121 An HCC Group companyCTM Training - ATE MTO Planning & Execution – Key Terms & Concepts Production Order Good’s Receipt (GR): • Production Order Good’s Receipt is done to declare production and to place finish good’s in to stock. • Here production good’s are places in special stock with reference to a particular sales order. • Production Order GR is integrated with Store and Account departments. • Target Cost is updated in a production order for GR Quantity delivered. • With WIP batch (Sohar Factory only): GR Batches consumes preceding WIP batches.
Page 122 An HCC Group companyCTM Training - ATE MTO Planning & Execution – Material Document
Page 123 An HCC Group companyCTM Training - ATE MTO Planning & Execution – Key Terms & Concepts Sales Order Stock Transfer: • Sales Order stock can be transferred from one sales order to another, by a separate transaction. • Unrestricted stock can be transferred to Sales Order stock, by a separate transaction. • Sales Order stock can be transferred to Unrestricted stock, by a separate transaction.
Page 124 An HCC Group companyCTM Training - ATE MTO Planning & Execution – Key Terms & Concepts Production Order Locking: • Production Order is temporary restricted for transactions by locking production order. • Once decision is to continue production, production order is un-locked Production Order Technical Completion (TECO): • Production Order is logistically completed at the end of the production activities. • TECO system status is updated once production order is technically completed. • GI, Production Confirmation and GR is not possible once production order • ‘DAC’ (Disallow Cost) user status is updated once technical completion is done. Authorization is required to revert this user status.
Page 125 An HCC Group companyCTM Training - ATE MTO Planning & Execution – Key Terms & Concepts Production Order Settlement: • Technical completion is prerequisite to settle production order. • Production Order CO settlement is done at the end of period i.e. at the end of month by costing person. Production order balance becomes zero after production order settlement. Production Order Business Completion (CLSD): • Production Order business completion is done once production order is settled. Business completion is possible only if Production order balance becomes zero. • This activity is normally carried out by Costing person.
Page 126 An HCC Group companyCTM Training - ATE Agenda  Objective  General Information  PP SAP Org. Structure  List of Processes  Process – Make To Order Planning & Execution  Sub Processes  Key Terms & Concepts  Process flow with steps & Reports  Scenarios in Process  Highlights of process  Process Change  SAP T-codes & Master data to be used  DMS documents to be attached  Exercise  Assessment Questionnaire
Page 127 An HCC Group companyCTM Training - ATE ATE Group – Process Matrix
Page 128 An HCC Group companyCTM Training - ATE MTO Planning & Execution – Process Flow
Page 129 An HCC Group companyCTM Training - ATE MTO Planning & Execution – Process Flow
Page 130 An HCC Group companyCTM Training - ATE MTO-ATO Planning & Execution – Steps & Reports
Page 131 An HCC Group companyCTM Training - ATE MTO-ATO Planning & Execution – Steps & Reports
Page 132 An HCC Group companyCTM Training - ATE MTO Sales Ord. MRP Planning & Execution – Steps & Reports
Page 133 An HCC Group companyCTM Training - ATE MTO Sales Ord. MRP Planning & Execution – Steps & Reports
Page 134 An HCC Group companyCTM Training - ATE MTO Sales Ord. MRP Planning & Execution – Steps & Reports
Page 135 An HCC Group companyCTM Training - ATE Agenda  Objective  General Information  PP SAP Org. Structure  List of Processes  Process – Make To Order Planning & Execution  Sub Processes  Key Terms & Concepts  Process flow with steps & Reports  Scenarios in Process  Highlights of process  Process Change  SAP T-codes & Master data to be used  DMS documents to be attached  Exercise  Assessment Questionnaire
Page 136 An HCC Group companyCTM Training - ATE MTO Planning & Execution - Scenarios MTO Planning: A. MTO Planning • MTO Planning – With Individual and Collective Procurement • MTO Planning – With Collective Procurement B. MTO Execution • MTO
Page 137 An HCC Group companyCTM Training - ATE Agenda  Objective  General Information  PP SAP Org. Structure  List of Processes  Process – Make To Order Planning & Execution  Sub Processes  Key Terms & Concepts  Process flow with steps & Reports  Scenarios in Process  Highlights of process  Process Change  SAP T-codes & Master data to be used  DMS documents to be attached  Exercise  Assessment Questionnaire
Page 138 An HCC Group companyCTM Training - ATE MTO Planning & Execution - Highlights MRP Group: • MRP group: Z002 - MTO (20) MRP Strategy: • MRPP Strategy: 20
Page 139 An HCC Group companyCTM Training - ATE MTO Planning & Execution - Highlights Planned Order Profile: • Planned Order Profile: KD Production Order GI: • Production Order is Debited at the time of Good’s Issue Production Order Confirmation: • Production Order is Debited at the time of Production Operation Confirmation
Page 140 An HCC Group companyCTM Training - ATE MTO Planning & Execution - Highlights Production Order GR: • Production Order is Credited at the time of Production Good’s Receipt Production Order Variance: • Production Order variance is calculated on the basis of Target Cost. • Production Target Cost Vs. Actual Cost and Target Qty Vs. Actual Qty is analyzed • Difference between Target cost and Actual Cost is settled as per production order settlement rule, on production variance account and cost center.
Page 141 An HCC Group companyCTM Training - ATE Agenda  Objective  General Information  PP SAP Org. Structure  List of Processes  Process – Make To Order Planning & Execution  Sub Processes  Key Terms & Concepts  Process flow with steps & Reports  Scenarios in Process  Highlights of process  Process Change  SAP T-codes & Master data to be used  DMS documents to be attached  Exercise  Assessment Questionnaire
Page 142 An HCC Group companyCTM Training - ATE ‘MTO – Sales Order MRP’ Planning & Execution – Process Change 1. Sales Order MRP Run (MD50) 2. MRP List (MD05) 3. Stock Requirement List (MD04) 4. Planned Order Maintenance 5. Capacity Planning 6. Capacity Leveling 7. Planned Order Conversion to Production Order (Partial / Complete) 8. Planned Order Conversion to Purchase Requisition – External Procurement 9. Production Order Capacity Planning 10. Production Order Capacity Evaluation 11. Production Order Release
Page 143 An HCC Group companyCTM Training - ATE ‘MTO – Sales Order MRP’ Planning & Execution – Process Change 12. Raw Material Availability Check – For a particular production order (lot). 13. Good’s Issue – Actual Qty for a particular production order (lot). 14. Activity Confirmation – Actual Machine/Manpower Hrs for a particular production order (lot). 15. Sales Order Cost Run – ‘ZFIN’ material type. 16. Good’s Receipt – Good’s Receipt to declare Stock of Finish Good for a particular production order (lot). 17. Activity Confirmation – Actual Overheads for a particular production order (lot). 18. Production Order (lot) - Target Cost Vs. Actual Cost Analysis 19. Production Order Technical Completion 20. Production Order Settlement
Page 144 An HCC Group companyCTM Training - ATE Agenda  Objective  General Information  PP SAP Org. Structure  List of Processes  Process – Make To Order Planning & Execution  Sub Processes  Key Terms & Concepts  Process flow with steps & Reports  Scenarios in Process  Highlights of process  Process Change  SAP T-codes & Master data to be used  DMS documents to be attached  Exercise  Assessment Questionnaire
Page 145 An HCC Group companyCTM Training - ATE MTO Planning & Execution - Transaction Codes
Page 146 An HCC Group companyCTM Training - ATE MTO Planning & Execution - Transaction Codes
Page 147 An HCC Group companyCTM Training - ATE MTO Planning & Execution - Transaction Codes
Page 148 An HCC Group companyCTM Training - ATE MTO Planning & Execution – Master Data 1. Material Master – (Finish Good’s, Raw Materials) 2. Bill Of Material – (Material BOM, Sales Order BOM) 3. Work Center 4. Routing

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3.pp level iii training ppt block&precasting, crusher

  • 1. PP End User Training – SAP (Level – 3) 16th December - 2013
  • 2. Page 2 An HCC Group companyCTM Training - ATEPresentation Title This presentation contains certain forward looking statements concerning future business prospects and profitability of Highbar Technologies Limited, which are subject to a number of risks and uncertainties and actual results could materially differ from those in such forward looking statements, important developments that could affect the company's operations include a downtrend in the information technology and infrastructure sectors, significant changes in political and economic environment in India, tax laws, labor relations, litigation etc. The company does not undertake to make any announcement in case any of these forward looking statements become materially incorrect in future or update any forward looking statements made from time to time by or on behalf of the company. All rights reserved. Copyright with Highbar Technologies Limited. Highbar is a trademark of Highbar Technologies Limited & other names, logos are trademarks of their respective owners. DISCLAIMER
  • 3. Page 3 An HCC Group companyCTM Training - ATE Agenda  Objective  General Information  PP SAP Org. Structure  List of Processes  Process  Sub Processes  Key Terms & Concepts  Process flow with steps & Reports  Scenarios in Process  Highlights of process  Process Change  SAP T-codes & Master data to be used  DMS documents to be attached  Exercise  Assessment Questionnaire
  • 4. Page 4 An HCC Group companyCTM Training - ATE Objective • Should be able to execute the Steps of process in the system • Understand end to end process with integration with Processes • Understand the process integration with other systems • Understand the validations & controls in system.
  • 5. Page 5 An HCC Group companyCTM Training - ATE Agenda  Objective  General Information  PP SAP Org. Structure  List of Processes  Process  Sub Processes  Key Terms & Concepts  Process flow with steps & Reports  Scenarios in Process  Highlights of process  Process Change  SAP T-codes & Master data to be used  DMS documents to be attached  Exercise  Assessment Questionnaire
  • 6. Page 6 An HCC Group companyCTM Training - ATE General Information • Current Stage of the project • Landscape details for testing • Other information • Schedule of Training
  • 7. Page 7 An HCC Group companyCTM Training - ATE General Inforn.– Road Map Of ATE SAP Implementation Project Preparation Business Blueprint Realization Final Preparation Go-live & Support Training-Level1 Workshop System design BPD System handing over On going support Prepare Project Plan Receive hardware Receive software Mobilize project team ‘Business Projects’ scope AS-IS Study/Clarification 1 2 3 4 5 O n g o i n g k n o w l e g d e t r a n s f e r b e t w e e n H I G H B A R a n d A T E C o r e t e a m Enabled project Team System understanding & Gap identification Understanding and concept s Buy In Documentation and end user comfort Ongoing support and continuous improvement End user training Finalize cutover data Finalize master data Developments Internal System testing – SIT - 1 CTM Training 18/11/2012 09/02/2013 08/05/2013 05/07/2013 06/07/2013 Stabilization & BI- BO Impl. 6 System Config 18/11/2012 10/03/2013 30/11/2013 31/12/2013 09/01/2014 Completed In process Planned date Revised Date LEGEND 16.12.2013 UAT
  • 8. Page 8 An HCC Group companyCTM Training - ATE Stores Unrestricted stock at Storage Location General Information – Landscape details for Testing Contractor Client No 100 Configuration ----------------------- Client No 120/150 ABAP development Development Server Client No 200 CTM Training & SIT - Testing ----------------------- Client No 210 End User Quality Server Client No 300 Production Server
  • 9. Page 9 An HCC Group companyCTM Training - ATE General Information – Other • Attend the full sessions of the training • Please make this sessions interactive • Carry out the testing by the way of exercises given in training • Appraise process owners about change processes if required. • Practice in system by executing the transaction in system post training • We should discourage the discussions around the process mapped in system • Process observations if any shall be recorded separately for clarification later
  • 10. Page 10 An HCC Group companyCTM Training - ATE General Information – Schedule of Training
  • 11. Page 11 An HCC Group companyCTM Training - ATE Agenda  Objective  General Information  PP SAP Org. Structure  List of Processes  Process  Sub Processes  Key Terms & Concepts  Process flow with steps & Reports  Scenarios in Process  Highlights of process  Process Change  SAP T-codes & Master data to be used  DMS documents to be attached  Exercise  Assessment Questionnaire
  • 12. Page 12 An HCC Group companyCTM Training - ATE PP Organization Structure
  • 13. Page 13 An HCC Group companyCTM Training - ATE PP Organization Structure - Plant
  • 14. Page 14 An HCC Group companyCTM Training - ATE PP Organization Structure – Storage Location
  • 15. Page 15 An HCC Group companyCTM Training - ATE Organizational Structure - Plant
  • 16. Page 16 An HCC Group companyCTM Training - ATE Organizational Structure - Plant
  • 17. Page 17 An HCC Group companyCTM Training - ATE Organizational Structure – Storage Location
  • 18. Page 18 An HCC Group companyCTM Training - ATE Organizational Structure – Storage Location
  • 19. Page 19 An HCC Group companyCTM Training - ATE Organizational Structure – Storage Location
  • 20. Page 20 An HCC Group companyCTM Training - ATE Organizational Structure – Storage Location
  • 21. Page 21 An HCC Group companyCTM Training - ATE Agenda  Objective  General Information  PP SAP Org. Structure  List of Processes  Process  Sub Processes  Key Terms & Concepts  Process flow with steps & Reports  Scenarios in Process  Highlights of process  Process Change  SAP T-codes & Master data to be used  DMS documents to be attached  Exercise  Assessment Questionnaire
  • 22. Page 22 An HCC Group companyCTM Training - ATE  PP Master Data  Long Term Planning ( Block,Interlock,Kerbstone,Crusher)  Make To Stock production planning & execution (Block,Interlock,Kerbstone,Crusher)  Make To Order production planning & execution – Sales Order MRP ( Pre-casting ) List of Processes
  • 23. Page 23 An HCC Group companyCTM Training - ATE Agenda  Objective  General Information  PP SAP Org. Structure  List of Processes  Process - PP Master Data  Sub Processes  Key Terms & Concepts  Process flow with steps & Reports  Scenarios in Process  Highlights of process  Process Change  SAP T-codes & Master data to be used  DMS documents to be attached  Exercise  Assessment Questionnaire
  • 24. Page 24 An HCC Group companyCTM Training - ATE PP Master Data – Sub Processes Production Planning & Control – Master Data  Maintain Bill Of Material  Maintain Work center  Maintain Routing Interdepartmental – Master Data  Activity Master  Cost Center
  • 25. Page 25 An HCC Group companyCTM Training - ATE Agenda  Objective  General Information  PP SAP Org. Structure  List of Processes  Process - PP Master Data  Sub Processes  Key Terms & Concepts  Process flow with steps & Reports  Scenarios in Process  Highlights of process  Process Change  SAP T-codes & Master data to be used  DMS documents to be attached  Exercise  Assessment Questionnaire
  • 26. Page 26 An HCC Group companyCTM Training - ATE PP Master Data – Key Terms & Concepts Material Master: • Material Master contains all the information, for all the material‘s, that company Procures, Produces, Stores and Sales. • Material Type (Similar Basic Attributes) - Raw Material (ZRAW) and FG (ZFIN). • Production Area related Information – Basic Data1, MRP1, MRP2, MRP3, MRP4 & Work Scheduling
  • 27. Page 27 An HCC Group companyCTM Training - ATE PP Master Data – Key Terms & Concepts Bill Of Material: • The Bill Of Material is a complete formally structured list of the components that make up a product. • Different BOM can be used – Company Usage Area wise e.g. Costing, Production etc. • BOM Header: Base Quantity, Active/Inactive Status • BOM Item Details: Material No, Quantity, UOM, Item Category, Production plant. • BOM Data is used by activities MRP, Work Scheduling, Procurement, Product Costing. • Multi-Level Explosion: MRP, Product Cost and Production Order
  • 28. Page 28 An HCC Group companyCTM Training - ATE PP Master Data – Key Terms & Concepts Work Center: • Work center is the place where an operation or activity is carried out within a plant • Work center: Represents as general as geographical location or as specific as a particular M/C/Production Line within a department or Person or Group of Persons performing a job. • Based on Usage Selection: Decides different Task Lists e.g. Routing, Rate Routing & Insp Plan • Work Center: SAP Plant Level • Work Center View: Basic data, Default values, Capacities, Scheduling and Costing
  • 29. Page 29 An HCC Group companyCTM Training - ATE PP Master Data – Key Terms & Concepts Routing: • A routing contains the operations to be performed, their sequence and the various work centers involved to manufacture an item. • Routing: Standard Values (Times) for activities such as setup and processing. • Control Key for Internal or External Operations • Material Operation Components Assignment • Production resources / tools. • Inspection Characteristics (Inspection Specification)
  • 30. Page 30 An HCC Group companyCTM Training - ATE Agenda  Objective  General Information  PP SAP Org. Structure  List of Processes  Process - PP Master Data  Sub Processes  Key Terms & Concepts  Process flow with steps & Reports  Scenarios in Process  Highlights of process  Process Change  SAP T-codes & Master data to be used  DMS documents to be attached  Exercise  Assessment Questionnaire
  • 31. Page 31 An HCC Group companyCTM Training - ATE PP Master Data – Process Flow
  • 32. Page 32 An HCC Group companyCTM Training - ATE PP Master Data - Process Flow
  • 33. Page 33 An HCC Group companyCTM Training - ATE Agenda  Objective  General Information  PP SAP Org. Structure  List of Processes  Process - PP Master Data  Sub Processes  Key Terms & Concepts  Process flow with steps & Reports  Scenarios in Process  Highlights of process  Process Change  SAP T-codes & Master data to be used  DMS documents to be attached  Exercise  Assessment Questionnaire
  • 34. Page 34 An HCC Group companyCTM Training - ATE PP Master Data - Scenarios Bill Of Material (BOM): • Standard Bill Of Material Sales Order Bill Of Material (BOM): • Sales Order BOM Work center • Work Center Routing • Standard Routing
  • 35. Page 35 An HCC Group companyCTM Training - ATE Agenda  Objective  General Information  PP SAP Org. Structure  List of Processes  Process - PP Master Data  Sub Processes  Key Terms & Concepts  Process flow with steps & Reports  Scenarios in Process  Highlights of process  Process Change  SAP T-codes & Master data to be used  DMS documents to be attached  Exercise  Assessment Questionnaire
  • 36. Page 36 An HCC Group companyCTM Training - ATE PP Master Data - Highlights Material Master: Material Types: ZRAW, ZFIN Price Control ZRAW: ‘V’ Moving Average Price Price Control ZFIN: ‘S’ Standard Price Material BOM: Material BOM Usage: 1 i.e. Production
  • 37. Page 37 An HCC Group companyCTM Training - ATE PP Master Data - Highlights Sales Order BOM: Material BOM Usage: 3 i.e. Universal Work center: Work Center Category: 0001 i.e. Machine Routing: Task List Type: N i.e. Routing
  • 38. Page 38 An HCC Group companyCTM Training - ATE Agenda  Objective  General Information  PP SAP Org. Structure  List of Processes  Process - PP Master Data  Sub Processes  Key Terms & Concepts  Process flow with steps & Reports  Scenarios in Process  Highlights of process  Process Change  SAP T-codes & Master data to be used  DMS documents to be attached  Exercise  Assessment Questionnaire
  • 39. Page 39 An HCC Group companyCTM Training - ATE ‘MTS PP’ Master Data – Process Change 1. ‘ZFIN’ & ‘ZRAW’ Material Type Material Masters Maintenance with MRP Parameters 2. Cross Plant Planning: Special Procurement Key Maintenance in ‘ZFIN’ material type material master at receiving plant. 3. Joint Production: Co-Product setting and Cost Apportion Structure Maintenance in ‘ZFIN’ material type material master. 4. Work center creation with available capacity requirements for representing total Batching Plant Production Capacity. 5. Work center creation with cost center & activity master details 6. Routing creation with Planned Activity Values
  • 40. Page 40 An HCC Group companyCTM Training - ATE ‘MTO PP’ Master Data – Process Change 1. ‘ZFIN’ & ‘ZRAW’ Material Type Material Masters Maintenance with MRP Parameters 2. ‘ZRAW’ Material Type Maintenance with Procurement details i.e. Individual and Collective. 3. Work center creation with available capacity requirements for representing total Batching Plant Production Capacity. 4. Work center creation with cost center & activity master details 5. Routing creation with Planned Activity Values
  • 41. Page 41 An HCC Group companyCTM Training - ATE Agenda  Objective  General Information  PP SAP Org. Structure  List of Processes  Process - PP Master Data  Sub Processes  Key Terms & Concepts  Process flow with steps & Reports  Scenarios in Process  Highlights of process  Process Change  SAP T-codes & Master data to be used  DMS documents to be attached  Exercise  Assessment Questionnaire
  • 42. Page 42 An HCC Group companyCTM Training - ATE PP Master Data - Transaction Codes
  • 43. Page 43 An HCC Group companyCTM Training - ATE PP Master Data - Transaction Codes
  • 44. Page 44 An HCC Group companyCTM Training - ATE PP Master Data - Transaction Codes
  • 45. Page 45 An HCC Group companyCTM Training - ATE Agenda  Objective  General Information  PP SAP Org. Structure  List of Processes  Process – Long Term Planning  Sub Processes  Key Terms & Concepts  Process flow with steps & Reports  Scenarios in Process  Highlights of process  Process Change  SAP T-codes & Master data to be used  DMS documents to be attached  Exercise  Assessment Questionnaire
  • 46. Page 46 An HCC Group companyCTM Training - ATE Long Term Planning – Key Terms & Concepts Long Term Planning: • Long term planning is used to analyse the production capacity load situation and material dependent requirements required for the production. Duration of LTP analysis can be from a one month to the years, subject to the realistic sales and production projections availability. Planning Scenario: • Planning scenario to determines the control parameters for long-term planning. This includes the plant where long-term planning is to be carried out, the planning period, and the independent requirements versions to be planned. Planning Scenario represents a particular division or a particular business area. Inactive Planned Independent Requirements Version : • LTP is carried out with inactive Planned Independent Requirements version. • Version ‘02’ is used for this purpose.
  • 47. Page 47 An HCC Group companyCTM Training - ATE Long Term Planning – Key Terms & Concepts LTP MRP Run (MS02 or MSBT): • Long term planning MRP Run is carried out separately i.e. It is not part of operative planning. LTP MRP run can be carried out in foreground MS02 or background MSBT. Frequency of background MRP Run can be monthly or multiple months. LTP Evaluation (MS05 or MS04): • Long term planning MRP evaluation is carried out separately i.e. It is not part of operative planning. LTP evaluation is done once MRP Run takes place or it can be dynamically done as required. LTP Material Analysis (MCEC/MCEB): • Long term planning Material Analysis is possible only if material master is created with procurement type ‘F’.
  • 48. Page 48 An HCC Group companyCTM Training - ATE Agenda  Objective  General Information  PP SAP Org. Structure  List of Processes  Process – Long Term Planning  Sub Processes  Key Terms & Concepts  Process flow with steps & Reports  Scenarios in Process  Highlights of process  Process Change  SAP T-codes & Master data to be used  DMS documents to be attached  Exercise  Assessment Questionnaire
  • 49. Page 49 An HCC Group companyCTM Training - ATE Long Term Planning - Process Flow
  • 50. Page 50 An HCC Group companyCTM Training - ATE Long Term Planning – Steps & Reports
  • 51. Page 51 An HCC Group companyCTM Training - ATE Long Term Planning – Steps & Reports
  • 52. Page 52 An HCC Group companyCTM Training - ATE Agenda  Objective  General Information  PP SAP Org. Structure  List of Processes  Process – Long Term Planning  Sub Processes  Key Terms & Concepts  Process flow with steps & Reports  Scenarios in Process  Highlights of process  Process Change  SAP T-codes & Master data to be used  DMS documents to be attached  Exercise  Assessment Questionnaire
  • 53. Page 53 An HCC Group companyCTM Training - ATE Long Term Planning - Scenarios • LTP With Capacity Planning & Material Analysis
  • 54. Page 54 An HCC Group companyCTM Training - ATE Agenda  Objective  General Information  PP SAP Org. Structure  List of Processes  Process – Long Term Planning  Sub Processes  Key Terms & Concepts  Process flow with steps & Reports  Scenarios in Process  Highlights of process  Process Change  SAP T-codes & Master data to be used  DMS documents to be attached  Exercise  Assessment Questionnaire
  • 55. Page 55 An HCC Group companyCTM Training - ATE Long Term Planning - Highlights Current Stock: • LTP Considers current material stock during planning. Firm Receipts: • LTP Considers current firm receipts e.g. purchase orders, production orders from operative planning. • Firm Purchase Requisitions and firm planned orders are also considered during LTP planning Customer Receipts: • LTP Considers current customer orders from operative planning LTP Capacity Analysis (CM38): • LTP Capacity Analysis is done to analyze any future bottlenecks in terms of machine capacity availability.
  • 56. Page 56 An HCC Group companyCTM Training - ATE Long Term Planning - Highlights LTP Material Analysis (MCEC & MCEB): • LTP Material Analysis is done for a particular material or for a particular material group. • As per material forecasting PO Value, Order Quantity and PO Price is possible to analyze.
  • 57. Page 57 An HCC Group companyCTM Training - ATE Agenda  Objective  General Information  PP SAP Org. Structure  List of Processes  Process – Long Term Planning  Sub Processes  Key Terms & Concepts  Process flow with steps & Reports  Scenarios in Process  Highlights of process  Process Change  SAP T-codes & Master data to be used  DMS documents to be attached  Exercise  Assessment Questionnaire
  • 58. Page 58 An HCC Group companyCTM Training - ATE Long Term Planning – Process Change 1. ‘ZFIN’ & ‘ZRAW’ Material Type Material Masters Maintenance with MRP Parameters 2. Cross Plant Planning: Special Procurement Key Maintenance in ‘ZFIN’ material type material master at receiving plant. 3. Work center creation with LTP Setting 4. Work center creation with available capacity requirements for representing total available Production Capacity. 5. Routing creation with Planned Activity Values – Capacity Planning 6. LTP – Planning Scenario Creation and Maintenance (MS31/MS32/MS3) 7. LTP – Inactive Version Planned Independent Creation (MD61)
  • 59. Page 59 An HCC Group companyCTM Training - ATE Long Term Planning – Process Change 8. LTP – MRP Run (MS02) 9. LTP – Stock Requirement List (MS04) 10. LTP – MRP List (MS05) 11. LTP – Setting Purchase Info Records 12. LTP Material Analysis (MCEC/MCEB) 13. LTP Work center Capacity Planning (CM38) Operative Planning: 14. ‘ZRAW’ Material Type - LTP Dependent Requirements Copy to Operative Planning (MS66) 15. ‘ZFIN’ Material Type – LTP Planned Independent Requirements Copy to Operative Planning (MD61)
  • 60. Page 60 An HCC Group companyCTM Training - ATE Agenda  Objective  General Information  PP SAP Org. Structure  List of Processes  Process – Long Term Planning  Sub Processes  Key Terms & Concepts  Process flow with steps & Reports  Scenarios in Process  Highlights of process  Process Change  SAP T-codes & Master data to be used  DMS documents to be attached  Exercise  Assessment Questionnaire
  • 61. Page 61 An HCC Group companyCTM Training - ATE Long Term Planning - Transaction Codes
  • 62. Page 62 An HCC Group companyCTM Training - ATE Long Term Planning – Master Data 1. Material Master – (Finish Good’s, Raw Materials) 2. Bill Of Material – Material BOM 3. Work Center 4. Routing
  • 63. Page 63 An HCC Group companyCTM Training - ATE Agenda  Objective  General Information  PP SAP Org. Structure  List of Processes  Process – Make To Stock Planning & Execution  Sub Processes  Key Terms & Concepts  Process flow with steps & Reports  Scenarios in Process  Highlights of process  Process Change  SAP T-codes & Master data to be used  DMS documents to be attached  Exercise  Assessment Questionnaire
  • 64. Page 64 An HCC Group companyCTM Training - ATE MTS Planning & Execution – Sub Processes 1. Make To Stock Planning & Execution with Planning Strategy 10 2. Make To Stock Planning & Execution with Joint Production ( Crusher )
  • 65. Page 65 An HCC Group companyCTM Training - ATE Agenda  Objective  General Information  PP SAP Org. Structure  List of Processes  Process – Make To Stock Planning & Execution  Sub Processes  Key Terms & Concepts  Process flow with steps & Reports  Scenarios in Process  Highlights of process  Process Change  SAP T-codes & Master data to be used  DMS documents to be attached  Exercise  Assessment Questionnaire
  • 66. Page 66 An HCC Group companyCTM Training - ATE MTS Planning & Execution – Key Terms & Concepts Make To Stock: • Make To Stock production environment produces good’s, products based on sales or production forecast. The production planning and execution activities takes place before receipt of firm customer orders. With this production environment it is possible to respond to customer orders fast with short lead time. Demand Management: • Demand Management consists of creation of planned independent requirements based on sales or production forecast. PIR are transferred to production planning & execution once MRP run takes place. MRP Run: • MRP i.e. Material Requirement Planning ensures material availability for in-house and external procurements. It transfers MTS requirements from demand management as well as a particular sales order requirements to production planning and execution. MRP Run also takes care of special procurement e.g. cross plant planning.
  • 67. Page 67 An HCC Group companyCTM Training - ATE MTS Planning & Execution – key Terms & Concepts Cross Plant Planning: • Cross plant planning insures stock transfer reservations across production plant. During MRP Run at receiver plant, stock transfer reservations are created in sender plant. The stock transfer can be done from available stock or if shortage is there, then production is done against stock transfer reservations. Special procurement key 40, 41 and 42 is used for this purpose. Planned Order: • Planned Order is generated after MRP Run for in-house production as well as for external procurements. Capacity planning (finite scheduling) is done for in-house production on the basis of Planned order. Material availability is checked on the basis of planned order. Planned Orders are further converted to production orders for in-house production and to purchased orders for external procurements. • Planned Orders are changed or deleted during MRP run • Planned Order can be manually generated if MRP run is not applicable in process. • Firm planned orders are not changed or deleted during MRP run.
  • 68. Page 68 An HCC Group companyCTM Training - ATE MTS Planning & Execution – Planned Order
  • 69. Page 69 An HCC Group companyCTM Training - ATE MTS Planning & Execution – Key Terms & Concepts Joint Production (Crusher Only): • Joint Production SAP functionality is applicable when there is requirement to simultaneously produce multiple finish good’s materials. Total cost of production is distributed on all valuated finish good’s produced. Co-Product: • Co-Product are valuated materials produced along with main finish good. Total Cost of production is apportioned on co-product. Cost Apportion Structure: • Cost Apportion structure is created in main finish good material master. Total cost of production is apportioned on main production material and co-products as per this cost-apportion structure. Total of equivalence numbers for all FG materials in cost apportion structure is equal to 1000. Bill of material is the basis for defining cost-apportion structure.
  • 70. Page 70 An HCC Group companyCTM Training - ATE MTS Planning & Execution – Co-Product
  • 71. Page 71 An HCC Group companyCTM Training - ATE MTS Planning & Execution – Cost Apportion Structure
  • 72. Page 72 An HCC Group companyCTM Training - ATE MTS Planning & Execution – Key Terms & Concepts Production Order: • Production order is created, to start the production of a material within a plant and to specify the material and quantity that will be produced. It decides the work location (capacity) that is used, which operations are required and the date on which production takes place. It also defines the Planned/Target production cost for the given production quantity. • Production Orders are considered as firm requirements. • Production order is released for production as per production plan. Production Order Type: • Production Order type decides control parameters for a particular production order. • Production Order types are configured in background. • Production Order Type defined at a particular division level. • Production Order type decides number range. Internal number range is followed at client level.
  • 73. Page 73 An HCC Group companyCTM Training - ATE MTS Planning & Execution – Key Terms & Concepts Production Order System Status • Production Order system status is automatically updated once a particular business transaction is carried out. • It is not possible to modify any of the production order system status. Production Order User Status • Production Order user status is automatically updated once a particular business transaction is carried out. • It is possible to modify any of the production order user status. • User status is activated based on business transaction • Authorization is required to modify any of the production order user status.
  • 74. Page 74 An HCC Group companyCTM Training - ATE MTS Planning & Execution – System Status/User Status
  • 75. Page 75 An HCC Group companyCTM Training - ATE MTS Planning & Execution – Production Order
  • 76. Page 76 An HCC Group companyCTM Training - ATE MTS Planning & Execution – Production Order Types
  • 77. Page 77 An HCC Group companyCTM Training - ATE MTS Planning & Execution – Key Terms & Concepts Production Order Good’s Issue (GI): • Raw Materials are issued against production order. Actual material consumption is booked during Good’s Issue against production order as and when material is physically issued. • Production Order GI is integrated with Store and Account departments. • Raw Material can be handled in batches. Production Order GI Transactions: • MIGO: Store person issue Good’s Issue through normal MM transaction.
  • 78. Page 78 An HCC Group companyCTM Training - ATE MTS Planning & Execution – Key Terms & Concepts Production Order Operation Confirmation: • Production Order Operation Confirmation i.e. Time Ticket Confirmation is done against production order. Machine and Manpower confirmation is done on daily basis. • Planned Production Overhead confirmation can be done on daily basis. Difference between plan and actual is posted at the end of the month once actual data is available by production order confirmation. • Yield, Scrap and Rework is booked during production execution. Scrap declared during production confirmation is not placed in stock.
  • 79. Page 79 An HCC Group companyCTM Training - ATE MTS Planning & Execution – Production Ord. Confirmation
  • 80. Page 80 An HCC Group companyCTM Training - ATE MTS Planning & Execution – Key Terms & Concepts Production Order Good’s Receipt (GR): • Production Order Good’s Receipt is done (TCode MIGO) to declare production and to place finish good’s in to stock. • Production Order GR is integrated with Store and Account departments. • Target Cost is updated in a production order for GR Quantity delivered. • With WIP batch (Sohar Factory only): GR Batches consumes preceding WIP batches. • Marble Tiles Line (TCode COWBHUWE): GR Posting with Handling Unit
  • 81. Page 81 An HCC Group companyCTM Training - ATE MTS Planning & Execution – Material Document
  • 82. Page 82 An HCC Group companyCTM Training - ATE MTS Planning & Execution – Key Terms & Concepts Production Order Locking: • Production Order is temporary restricted for transactions by locking production order. • Once decision is to continue production, production order is un-locked Production Order Technical Completion (TECO): • Production Order is logistically completed at the end of the production activities. • TECO system status is updated once production order is technically completed. • GI, Production Confirmation and GR is not possible once production order is technically completed. • ‘DAC’ (Disallow Cost) user status is updated once technical completion is done. Authorization is required to revert this user status.
  • 83. Page 83 An HCC Group companyCTM Training - ATE MTS Planning & Execution – Key Terms & Concepts Production Order Settlement: • Technical completion is prerequisite to settle production order. • Production Order CO settlement is done at the end of period i.e. at the end of month by costing person. Production order balance becomes zero after production order settlement. Production Order Business Completion (CLSD): • Production Order business completion is done once production order is settled. Business completion is possible only if Production order balance becomes zero. • This activity is normally carried out by Costing person.
  • 84. Page 84 An HCC Group companyCTM Training - ATE Agenda  Objective  General Information  PP SAP Org. Structure  List of Processes  Process – Make To Stock Planning & Execution  Sub Processes  Key Terms & Concepts  Process flow with steps & Reports  Scenarios in Process  Highlights of process  Process Change  SAP T-codes & Master data to be used  DMS documents to be attached  Exercise  Assessment Questionnaire
  • 85. Page 85 An HCC Group companyCTM Training - ATE ATE Group – Process Matrix
  • 86. Page 86 An HCC Group companyCTM Training - ATE MTS Planning & Execution – Process Flow
  • 87. Page 87 An HCC Group companyCTM Training - ATE MTS Planning & Execution – Process Flow
  • 88. Page 88 An HCC Group companyCTM Training - ATE MTS Planning & Execution – Steps & Reports
  • 89. Page 89 An HCC Group companyCTM Training - ATE MTS Planning & Execution – Steps & Reports
  • 90. Page 90 An HCC Group companyCTM Training - ATE MTS Planning & Execution – Steps & Reports
  • 91. Page 91 An HCC Group companyCTM Training - ATE Agenda  Objective  General Information  PP SAP Org. Structure  List of Processes  Process – Make To Stock Planning & Execution  Sub Processes  Key Terms & Concepts  Process flow with steps & Reports  Scenarios in Process  Highlights of process  Process Change  SAP T-codes & Master data to be used  DMS documents to be attached  Exercise  Assessment Questionnaire
  • 92. Page 92 An HCC Group companyCTM Training - ATE MTS Planning & Execution - Scenarios MTS Planning: A. MTS Planning • MTS Demand Management – Copy PIR from LTP Planning • MTS Manual Planned Order B. MTS Execution • MTS • MTS with Joint Production
  • 93. Page 93 An HCC Group companyCTM Training - ATE Agenda  Objective  General Information  PP SAP Org. Structure  List of Processes  Process – Make To Stock Planning & Execution  Sub Processes  Key Terms & Concepts  Process flow with steps & Reports  Scenarios in Process  Highlights of process  Process Change  SAP T-codes & Master data to be used  DMS documents to be attached  Exercise  Assessment Questionnaire
  • 94. Page 94 An HCC Group companyCTM Training - ATE MTS Planning & Execution - Highlights Planned Independent Creation: • Copy from LTP MRP Group: • MRP Group: Z004 - MTS (10) Manufacturing MRP Strategy: • MRP Strategy: 10
  • 95. Page 95 An HCC Group companyCTM Training - ATE MTS Planning & Execution - Highlights Planned Order Profile: • Planned Order Profile: LA Production Order GI: • Production Order is Debited at the time of Good’s Issue Production Order Confirmation: • Production Order is Debited at the time of Production Operation Confirmation
  • 96. Page 96 An HCC Group companyCTM Training - ATE MTS Planning & Execution - Highlights Production Order GR: • Production Order is Credited at the time of Production Good’s Receipt Production Order Variance: • Production Order variance is calculated on the basis of Target Cost. • Production Target Cost Vs. Actual Cost and Target Qty Vs. Actual Qty is analyzed • Difference between Target cost and Actual Cost is settled as per production order settlement rule, on production variance account and cost center.
  • 97. Page 97 An HCC Group companyCTM Training - ATE Agenda  Objective  General Information  PP SAP Org. Structure  List of Processes  Process – Make To Stock Planning & Execution  Sub Processes  Key Terms & Concepts  Process flow with steps & Reports  Scenarios in Process  Highlights of process  Process Change  SAP T-codes & Master data to be used  DMS documents to be attached  Exercise  Assessment Questionnaire
  • 98. Page 98 An HCC Group companyCTM Training - ATE MTS Planning & Execution – Process Change 1. Planned Dependent Requirement (MD61) - ‘ZFIN’ Material Type – LTP Planned Independent Requirements Copy to Operative Planning (MD61) 2. MRP Run (MD03/MDBT) 3. MRP List (MD05) 4. Stock Requirement List (MD04) 5. Planned Order Maintenance 6. Capacity Planning 7. Capacity Leveling 8. Planned Order Conversion to Production Order (Partial / Complete) 9. Production Order Capacity Planning 10. Production Order Capacity Evaluation 11. Production Order Release
  • 99. Page 99 An HCC Group companyCTM Training - ATE MTS Planning & Execution – Process Change 12. Raw Material Availability Check – For a particular production order (lot). 13. Good’s Issue – Actual Qty for a particular production order (lot). 14. Activity Confirmation – Actual Machine/Manpower Hrs for a particular production order (lot). 15. Target Cost Run – ‘ZFIN’ material type. 16. Good’s Receipt – Good’s Receipt to declare Stock of Finish Good for a particular production order (lot). 17. Activity Confirmation – Actual Overheads for a particular production order (lot). 18. Production Order (lot) - Target Cost Vs. Actual Cost Analysis 19. Production Order Technical Completion 20. Production Order Settlement
  • 100. Page 100 An HCC Group companyCTM Training - ATE MTS Planning & Execution – Process Change Operative Planning: 14. ‘ZRAW’ Material Type - LTP Dependent Requirements Copy to Operative Planning (MS66) 15. ‘ZRAW’ Material Type – Planning on the basis of Production Order Reservations.
  • 101. Page 101 An HCC Group companyCTM Training - ATE Agenda  Objective  General Information  PP SAP Org. Structure  List of Processes  Process – Make To Stock Planning & Execution  Sub Processes  Key Terms & Concepts  Process flow with steps & Reports  Scenarios in Process  Highlights of process  Process Change  SAP T-codes & Master data to be used  DMS documents to be attached  Exercise  Assessment Questionnaire
  • 102. Page 102 An HCC Group companyCTM Training - ATE MTS Planning & Execution - Transaction Codes
  • 103. Page 103 An HCC Group companyCTM Training - ATE MTS Planning & Execution - Transaction Codes
  • 104. Page 104 An HCC Group companyCTM Training - ATE MTS Planning & Execution - Transaction Codes
  • 105. Page 105 An HCC Group companyCTM Training - ATE MTS Planning & Execution – Master Data 1. Material Master – (Finish Good’s, Raw Materials) 2. Bill Of Material – (Material BOM) 3. Work Center 4. Routing
  • 106. Page 106 An HCC Group companyCTM Training - ATE Agenda  Objective  General Information  PP SAP Org. Structure  List of Processes  Process – Make To Order Planning & Execution  Sub Processes  Key Terms & Concepts  Process flow with steps & Reports  Scenarios in Process  Highlights of process  Process Change  SAP T-codes & Master data to be used  DMS documents to be attached  Exercise  Assessment Questionnaire
  • 107. Page 107 An HCC Group companyCTM Training - ATE MTO Planning & Execution – Sub Processes 1. Make To Order Planning & Execution with Sales Order MRP
  • 108. Page 108 An HCC Group companyCTM Training - ATE Agenda  Objective  General Information  PP SAP Org. Structure  List of Processes  Process – Make To Order Planning & Execution  Sub Processes  Key Terms & Concepts  Process flow with steps & Reports  Scenarios in Process  Highlights of process  Process Change  SAP T-codes & Master data to be used  DMS documents to be attached  Exercise  Assessment Questionnaire
  • 109. Page 109 An HCC Group companyCTM Training - ATE MTO Planning & Execution – Key Terms & Concepts Make To Order: • Make To Order production environment produces good’s, products based on sales orders. The production planning and execution activities takes place only after receipt of firm customer orders. With this production environment it is possible to respond to minimize production inventory as well as this process caters effectively to deliver finish good’s with short shelf life e.g. Ready Mix Concrete etc. Sales Order: • Sales Order is created against contract based on customer delivery Schedule and delivery confirmation. System treats each schedule line as a separate procurement item. Production is done separately against each schedule line.
  • 110. Page 110 An HCC Group companyCTM Training - ATE MTO Planning & Execution – Key Terms & Concepts Sales Order MRP Run: • MRP i.e. Material Requirement Planning ensures material availability for in-house and external procurements. It transfers customer requirements from a sales order requirements to production planning and execution. MRP Run also takes care of in-house production as well as external procurements. Planned Order: • Planned Order is generated after MRP Run for in-house production as well as for external procurements. Capacity planning (finite scheduling) is done for in-house production on the basis of Planned order. Material availability is checked on the basis of planned order. Planned Orders are further converted to production orders for in-house production and to purchased orders for external procurements. • Planned Orders are changed or deleted during MRP run • Planned Order can be manually generated if MRP run is not applicable in process. • Firm planned orders are not changed or deleted during MRP run.
  • 111. Page 111 An HCC Group companyCTM Training - ATE MTO Planning & Execution – Planned Order
  • 112. Page 112 An HCC Group companyCTM Training - ATE MTO Planning & Execution – Planned Order
  • 113. Page 113 An HCC Group companyCTM Training - ATE MTO Planning & Execution – Key Terms & Concepts Production Order: • Production order is created, to start the production of a material within a plant and to specify the material and quantity that will be produced. It decides the work location (capacity) that is used, which operations are required and the date on which production takes place. It also defines the Planned/Target production cost for the given production quantity. • Production Orders are considered as firm requirements. • Production order is released for production as per production plan. Production Order Type: • Production Order type decides control parameters for a particular production order. • Production Order types are configured in background. • Production Order Type defined at a particular division level. • Production Order type decides number range. Internal number range is followed at client level.
  • 114. Page 114 An HCC Group companyCTM Training - ATE MTO Planning & Execution – Key Terms & Concepts Production Order System Status • Production Order system status is automatically updated once a particular business transaction is carried out. • It is not possible to modify any of the production order system status. Production Order User Status • Production Order user status is automatically updated once a particular business transaction is carried out. • It is possible to modify any of the production order user status. • User status is activated based on business transaction • Authorization is required to modify any of the production order user status.
  • 115. Page 115 An HCC Group companyCTM Training - ATE MTO Planning & Execution – System Status/User Status
  • 116. Page 116 An HCC Group companyCTM Training - ATE MTO Planning & Execution – Production Order
  • 117. Page 117 An HCC Group companyCTM Training - ATE MTO Planning & Execution – Production Order Types
  • 118. Page 118 An HCC Group companyCTM Training - ATE MTO Planning & Execution – Key Terms & Concepts Production Order Good’s Issue (GI): • Raw Materials are issued against production order. Actual material consumption is booked during Good’s Issue against production order as and when material is physically issued. • Production Order GI is integrated with Store and Account departments. • System handles individual or collective procurements as per the setting in raw material, material master • Raw Material can be handled in batches. Production Order GI Transactions: 1. MIGO: Store person issue Good’s Issue through normal MM transaction. 2. CO11N (Sohar Marble Slab Line only): Material is issued through production order confirmation transaction. Here the input batches are linked with production order.
  • 119. Page 119 An HCC Group companyCTM Training - ATE MTO Planning & Execution – Key Terms & Concepts Production Order Operation Confirmation: • Production Order Operation Confirmation i.e. Time Ticket Confirmation is done against production order. Machine and Manpower confirmation is done on daily basis. • Planned Production Overhead confirmation can be done on daily basis. Difference between plan and actual is posted at the end of the month once actual data is available by production order confirmation. • Yield, Scrap and Rework is booked during production execution. Scrap declared during production confirmation is not placed in stock.
  • 120. Page 120 An HCC Group companyCTM Training - ATE MTO Planning & Execution – Production Ord. Confirmation
  • 121. Page 121 An HCC Group companyCTM Training - ATE MTO Planning & Execution – Key Terms & Concepts Production Order Good’s Receipt (GR): • Production Order Good’s Receipt is done to declare production and to place finish good’s in to stock. • Here production good’s are places in special stock with reference to a particular sales order. • Production Order GR is integrated with Store and Account departments. • Target Cost is updated in a production order for GR Quantity delivered. • With WIP batch (Sohar Factory only): GR Batches consumes preceding WIP batches.
  • 122. Page 122 An HCC Group companyCTM Training - ATE MTO Planning & Execution – Material Document
  • 123. Page 123 An HCC Group companyCTM Training - ATE MTO Planning & Execution – Key Terms & Concepts Sales Order Stock Transfer: • Sales Order stock can be transferred from one sales order to another, by a separate transaction. • Unrestricted stock can be transferred to Sales Order stock, by a separate transaction. • Sales Order stock can be transferred to Unrestricted stock, by a separate transaction.
  • 124. Page 124 An HCC Group companyCTM Training - ATE MTO Planning & Execution – Key Terms & Concepts Production Order Locking: • Production Order is temporary restricted for transactions by locking production order. • Once decision is to continue production, production order is un-locked Production Order Technical Completion (TECO): • Production Order is logistically completed at the end of the production activities. • TECO system status is updated once production order is technically completed. • GI, Production Confirmation and GR is not possible once production order • ‘DAC’ (Disallow Cost) user status is updated once technical completion is done. Authorization is required to revert this user status.
  • 125. Page 125 An HCC Group companyCTM Training - ATE MTO Planning & Execution – Key Terms & Concepts Production Order Settlement: • Technical completion is prerequisite to settle production order. • Production Order CO settlement is done at the end of period i.e. at the end of month by costing person. Production order balance becomes zero after production order settlement. Production Order Business Completion (CLSD): • Production Order business completion is done once production order is settled. Business completion is possible only if Production order balance becomes zero. • This activity is normally carried out by Costing person.
  • 126. Page 126 An HCC Group companyCTM Training - ATE Agenda  Objective  General Information  PP SAP Org. Structure  List of Processes  Process – Make To Order Planning & Execution  Sub Processes  Key Terms & Concepts  Process flow with steps & Reports  Scenarios in Process  Highlights of process  Process Change  SAP T-codes & Master data to be used  DMS documents to be attached  Exercise  Assessment Questionnaire
  • 127. Page 127 An HCC Group companyCTM Training - ATE ATE Group – Process Matrix
  • 128. Page 128 An HCC Group companyCTM Training - ATE MTO Planning & Execution – Process Flow
  • 129. Page 129 An HCC Group companyCTM Training - ATE MTO Planning & Execution – Process Flow
  • 130. Page 130 An HCC Group companyCTM Training - ATE MTO-ATO Planning & Execution – Steps & Reports
  • 131. Page 131 An HCC Group companyCTM Training - ATE MTO-ATO Planning & Execution – Steps & Reports
  • 132. Page 132 An HCC Group companyCTM Training - ATE MTO Sales Ord. MRP Planning & Execution – Steps & Reports
  • 133. Page 133 An HCC Group companyCTM Training - ATE MTO Sales Ord. MRP Planning & Execution – Steps & Reports
  • 134. Page 134 An HCC Group companyCTM Training - ATE MTO Sales Ord. MRP Planning & Execution – Steps & Reports
  • 135. Page 135 An HCC Group companyCTM Training - ATE Agenda  Objective  General Information  PP SAP Org. Structure  List of Processes  Process – Make To Order Planning & Execution  Sub Processes  Key Terms & Concepts  Process flow with steps & Reports  Scenarios in Process  Highlights of process  Process Change  SAP T-codes & Master data to be used  DMS documents to be attached  Exercise  Assessment Questionnaire
  • 136. Page 136 An HCC Group companyCTM Training - ATE MTO Planning & Execution - Scenarios MTO Planning: A. MTO Planning • MTO Planning – With Individual and Collective Procurement • MTO Planning – With Collective Procurement B. MTO Execution • MTO
  • 137. Page 137 An HCC Group companyCTM Training - ATE Agenda  Objective  General Information  PP SAP Org. Structure  List of Processes  Process – Make To Order Planning & Execution  Sub Processes  Key Terms & Concepts  Process flow with steps & Reports  Scenarios in Process  Highlights of process  Process Change  SAP T-codes & Master data to be used  DMS documents to be attached  Exercise  Assessment Questionnaire
  • 138. Page 138 An HCC Group companyCTM Training - ATE MTO Planning & Execution - Highlights MRP Group: • MRP group: Z002 - MTO (20) MRP Strategy: • MRPP Strategy: 20
  • 139. Page 139 An HCC Group companyCTM Training - ATE MTO Planning & Execution - Highlights Planned Order Profile: • Planned Order Profile: KD Production Order GI: • Production Order is Debited at the time of Good’s Issue Production Order Confirmation: • Production Order is Debited at the time of Production Operation Confirmation
  • 140. Page 140 An HCC Group companyCTM Training - ATE MTO Planning & Execution - Highlights Production Order GR: • Production Order is Credited at the time of Production Good’s Receipt Production Order Variance: • Production Order variance is calculated on the basis of Target Cost. • Production Target Cost Vs. Actual Cost and Target Qty Vs. Actual Qty is analyzed • Difference between Target cost and Actual Cost is settled as per production order settlement rule, on production variance account and cost center.
  • 141. Page 141 An HCC Group companyCTM Training - ATE Agenda  Objective  General Information  PP SAP Org. Structure  List of Processes  Process – Make To Order Planning & Execution  Sub Processes  Key Terms & Concepts  Process flow with steps & Reports  Scenarios in Process  Highlights of process  Process Change  SAP T-codes & Master data to be used  DMS documents to be attached  Exercise  Assessment Questionnaire
  • 142. Page 142 An HCC Group companyCTM Training - ATE ‘MTO – Sales Order MRP’ Planning & Execution – Process Change 1. Sales Order MRP Run (MD50) 2. MRP List (MD05) 3. Stock Requirement List (MD04) 4. Planned Order Maintenance 5. Capacity Planning 6. Capacity Leveling 7. Planned Order Conversion to Production Order (Partial / Complete) 8. Planned Order Conversion to Purchase Requisition – External Procurement 9. Production Order Capacity Planning 10. Production Order Capacity Evaluation 11. Production Order Release
  • 143. Page 143 An HCC Group companyCTM Training - ATE ‘MTO – Sales Order MRP’ Planning & Execution – Process Change 12. Raw Material Availability Check – For a particular production order (lot). 13. Good’s Issue – Actual Qty for a particular production order (lot). 14. Activity Confirmation – Actual Machine/Manpower Hrs for a particular production order (lot). 15. Sales Order Cost Run – ‘ZFIN’ material type. 16. Good’s Receipt – Good’s Receipt to declare Stock of Finish Good for a particular production order (lot). 17. Activity Confirmation – Actual Overheads for a particular production order (lot). 18. Production Order (lot) - Target Cost Vs. Actual Cost Analysis 19. Production Order Technical Completion 20. Production Order Settlement
  • 144. Page 144 An HCC Group companyCTM Training - ATE Agenda  Objective  General Information  PP SAP Org. Structure  List of Processes  Process – Make To Order Planning & Execution  Sub Processes  Key Terms & Concepts  Process flow with steps & Reports  Scenarios in Process  Highlights of process  Process Change  SAP T-codes & Master data to be used  DMS documents to be attached  Exercise  Assessment Questionnaire
  • 145. Page 145 An HCC Group companyCTM Training - ATE MTO Planning & Execution - Transaction Codes
  • 146. Page 146 An HCC Group companyCTM Training - ATE MTO Planning & Execution - Transaction Codes
  • 147. Page 147 An HCC Group companyCTM Training - ATE MTO Planning & Execution - Transaction Codes
  • 148. Page 148 An HCC Group companyCTM Training - ATE MTO Planning & Execution – Master Data 1. Material Master – (Finish Good’s, Raw Materials) 2. Bill Of Material – (Material BOM, Sales Order BOM) 3. Work Center 4. Routing