For Process Industry.

Configuration

- Create Order Type for Process Order - T.Code CORN

- Create Order Type Dependent Parameter - T.Code COR4
- Production Scheduling Profile - CORY
- Specify Scheduling Parameter - OPUZ
- Create Control Recipe Destination - O10C
- Create Process Massage Destination - O13C (Optional)
- Create Process Instruction Catagory - O12C (Optional)

Master Data
- Create BOM - CS01
- Create Resource - CRC1
- Create Master Recipe - C201

MRP :- MD61/MD20/MDBT/
MD01/MD02/MD03/
MD04/MD05/MD06/MD07
MD40/MD41/MD42/MD50.

Production Execution :-
- COR1 - Create Process Order Manual
- COR7 - Convert Plan Order to Process Order
- COR6N/CORZ/CORR - Order Confirmation
- CORS - Cancel Confirmation
- CORT - Display Confirmation
- CO53 - Control Recipe Monitor (Optional)
- CO55/CO60 - Maintain PI Sheet (Optional)
- CO54 - Process Massage Monitor (Optional)
- MB31 - Goods Receipt For Order
- COIK / MB1A / MIGO :- Goods Issue
- KKS1/KKS2 - Calculate Varience
- CO88 - Actual settlement
- COOISPI - Order Information System – PI

What is the significance of process order over production order?

Process instruction and messages. With referance to process order process instruction sheet can
be generated where you can get information about the range of values to be measured while
processing the material.This facility is not available with production order.

The major differences between master recipe and routing are: in a recipe,
1. You use operations and phases, and phases are more important than operations
2. You have to define control recipe destination
3. You can define process instruction
4. You have the chance to build relationship among phases
Introduction to SAP PPPI
Study Material Contributed by Ulhas Kavle - Senior SAP Consultant, Mahindra Satyam
 
Introduction to SAP PPPI - SAP Process Manufacturing
Introduction to SAP PPPI - Process Manufacturing
 
My definition to "Process manufacturing" is that, it is a form of an industry type, where the products
once manufactured, cannot be easily dis-assembled. It is also really not possible to rework the ill-
manufactured end products, back in to raw materials. For example products such as food products,
chemicals, medicine, Towels, Paper, Steel etc.
 
With the above definition of a process industry in prespective, SAP offers SAP PPPI or SAP PI which
can be used to implement business processes in a process industry. 
 
There are a many key differences between Process manufacturing and discrete manufacturing with
respect to manufacturing processes and SAP offerings.
 
Speaking of the key differences, the following points are slated here and explained in the next
section below:
 

 A Master Recipe is one of the key differences and all the individual differences revolve
around the master recipe. SAP PP-PI has a task list called as a Master Recipe vis-a-vis the
routings in the SAP PP. SAP uses the master recipe when creating the process order. The
purpose Routings and the Master Recipe is equal to a large extent, like scheduling, capacity
generations, generating planned costs and component scheduling. Though the major
difference between the master recipe and the routing is - a) embedding of the BOM in the
task list through the use of production versions, b) material quantity calculations, c) process
management which defines a standard interface between SAP and the shop floor to
communicate production and execution data.

 Process Management allowing an interface betwen SAP and the shop floor destinations.

 Process order related documentation.

  
Key Differences between SAP PPPI - Process Manufacturing & SAP PP - Discrete Manufacturing:
  
A detailed analysis of these difference is made all over the SAP PP PI Documentation. Though a start
is made here in this section to bring about the differences clearly before deep diving in to the article
in subsequent pages. The difference betwen SAP PP and PP PI is made only as an overview:
  
a) Production Versions and their use in Master Recipe
  
Vis-à-vis the routing or rate routing, the master recipe collects the operations and the BOM together
in one master data through the use of production version. The production version is exploded in the
recipe to pull in the material BOM.
 Bringing the BOM inside the task list helps in generating one more unique feature of a recipe called
the “Material Quantity Calculations”. The material quantity calculations helps to change the
component quantities and the header material quantity vis-à-vis each other and with respect to the
values of the active ingredients (batch classification specifications) of the components and the
header material.
 
Before creating the recipe, one should have a Production version created with at least the BOM
embedded in it, which will help adding the BOM to the recipe.
 
 Very Important Note – It seems to be a normal practice that the recipe group number is added to
the production version after it is created. So you may have to maintain the production version
information, firstly after the BOM creation and before the recipe creation and once after the recipe
creation so as to assign the Recipe group number to it.
  
b) The concept of phases and operations in a task list
 

 A master recipe carries a concept of operations assigned with phase’s  discrete

manufacturing which has only operation level details. The operations are thus mere place
holders of phases and carry no major importance in SAP PP PI.  

 The introduction of phases helps the organization to break down the activities on an
operation (as phases) and detail them out.

 The standard values/activities like the set-up time or duration or machine time etc; are
assigned to the phases in process manufacturing unlike discrete manufacturing where they
are assigned to the operation itself. This takes you to an obvious conclusion that the
confirmation in process manufacturing are carried out at the phase level rather than at
operation level.

 The concept of Relationships between phases of different operations or with the same
operation or even between two different material recipes helps in scheduling the process
orders (as per the relations set-up). The relationship between phases in SAP PP PI can be
correlated with parallel and alternate operation sequence set up in discrete manufacturing.

 The External operation processing is also carried out at the phase level and not at the
operation level.  

 Though one can assign inspection characteristics to both operations and phases.  

 Even the components of the BOM in SAP PPPI, are assigned to the phases and not the
operations, thus strengthening the fact that the phases govern over the operations.
 The work center or resource  are assigned to the operation level and all the phases
assigned to the operation uses the same  resource. A resource carries a QDR system, which
is the address of an external control system to which data has to be sent, in cases when the
control recipe destination is an external process control system. The QDR field can be
configured in SAP.
 The set up of the "process management functionality in SAP PP PI" through control recipe
destination, process instruction categories and process message categories is done at the
phase level. You can assign a unique control recipe destination to a phase and a set of
process instruction categories which are eventually downloaded to the respective
destinations as control recipe. This is explained in detail further down.
 
  c) The concept of Material list and Material Quantity Calculations in the Master Recipe
 
As discussed in the above paragraph the master recipe has an added capability to bring in the
material list or the BOM through the use of production versions. The presence of BOM in the recipe
allows SAP PP PI to add a functionality called as  "material quantity calculations" for the header
material as well as the components, where in you can change the component quantities and the
header material quantities based on the characteristics values of their respective batch classes
and through formulas written as macros.
  
d) Process Management
  
The master recipe also comes with a feature called as the process management, which is primary
differentiator between the Routing and the Recipe. 
 

 This features allows a clear communication or interface between SAP and the shop floor
destination to communicate production or execution related data between them. This
interface is a standard SAP defined interface and works with SAP sending process
instruction categories to the destination and the destination sending back execution data
to SAP for updation in SAP database.  

 Every phase in a master recipe has a shop floor destination or control recipe destination.
The process instructions are assigned to the phases; these process instructions carry
process notes, order details, phase details, component details, quality inspection details,
goods receipt details. The process instructions are bundled up into a control recipe and are
sent to the control recipe destination, which once sent to the shop floor operator or the
process control system, helps them to with the detailed information and instructions about
the order and initiates a trigger to start manufacturing activities.  

 The process instructions also contains information on the Process messages which are
supposed to be sent back to SAP (data requests), like the confirmation records for the
order; goods issue records for the order and goods receipts data for the order, inspection
results for the received goods etc. Eventually the processes messages post the data in SAP
tables using various BAPI’s and functional modules.  

 An “individual process instruction” for example – a process instruction for order

information, contains characteristics like the order number, plant code, order type, order
start date, order finish date, order reservation number, header batch number (if any) etc.
These characteristics carry the respective values. You can manually change/add the values
or have them populated by the system (for example for characteristics like order number,
order start date, order type etc ;) as per the process design. The characteristics used in
process instructions to carry values of various parameters are always assigned with a
characteristics group called as PPPI_INST. 

 The process instructions can be assigned to the master recipe with product or process
specific values assigned in them or they can be assigned to the control recipe destination
itself.

Assigning the process instructions to the control recipe destination would automatically
explode them in the process order and this avoids the effort of individually assigning them
at the material/plant level master recipes.

For process instruction attached to the destination, you could still assign values to them
but they would not be material specific and would be very generic in nature which is
applicable to the processes carried out at the destination.  

 The Process instructions are bundled up in a control recipe which is downloaded from SAP
 and sent the control system or the shop floor operator. The Recipient processes the process
order and sends activity completion process messages to the SAP system in the form of
process messages.  

 Correlation – One can correlate the process instructions as an examination Question Paper’
set for a particular grade with instructions and questions in it. This question paper (as
process instructions) is given to each and every student belonging to a particular grade (a
grade can be a control Recipe destination) along with the process message request to
answer the questions in a particular set time (consider the filled up answer sheet along with
the Roll number and grade as process messages which are requested back by the system).
The students are expected to carry out the activities of answering and appearing for the test
and in return submit the answer sheet as process message back to the examiner (the
examiner can be the SAP system which updates the completion information and marks in
SAP system). 

 Standard SAP in SAP PPPI is designed to have the recipient as a shop floor operator in SAP
itself, who completes the order detailing and manufacturing in PI SHEETS and sends back
the process messages to the SAP cockpits to process standard designed BAPI’s. On the other
hand if the recipient is a process control system outside of SAP, he can also receive or
request the instructions in a control recipe to aid in production and send back the messages
to SAP system through standard interfaces designed for such integrations between SAP and
the external shop floor control system.  

Figure 1
  
e) Use of Intra Materials in SAP PP PI
  
Use of Intra Materials in a key feature available both in process manufacturing and discrete
manufacturing; though it is predominantly talked about in process manufacturing since SAP PPPI
offers storage resources in between operations to store these intra materials. Intra Materials are
materials which are added to stock in between production and removed from stock when they are
issued to the next resource.
 f) Electronic Batch Record:
  
SAP PP PI provides a Facility for documentation & Optical Archiving of the Batch Related data of a
process order or order related data for future references. You can document or record all the
process order related activities of the process order.  

Control Recipe Destinations

Control recipe Destinations

 
Standard SAP has control recipe destinations which receive the process instructions and using which
the destination carries out the manufacturing and at the end of which they send back the process
messages to confirm their production activities or production status on a real time basis.
 
The control recipe destinations are assigned to the individual phases of an operation; which means
that every phase in a master recipe can carry different control recipe destinations. One control
recipe is created for a given destination and order combination.
 
The destinations or recipients of the process instructions can be SAP destinations or external
process control system destinations. If the destination is in SAP itself, then it can be a shop floor
operator/operator group at a plant or a production line or shop floor operator/operator group for a
specific activity, executing the phase; where as if the destination is an external process control
system outside of SAP, then the process instructions & process messages are interfaced with that
external system.
 
The definition of the control recipe destination needs configuring the destination type, address of
the destination (in external system, the address is the RFC destination of the process control
systems).
 
Control SAP External Control System
Recipe
Destination
 
1&4 Destination lies in SAP ERP  
system
 
2&3   Destinations lies outside of SAP ERP
system and is called as an External
Control System
 
 
Control Recipe Destinations Type 1 & 4 - Destination located in SAP ECC System
 
 For shop floor destinations which are in SAP itself, there are 2 different types of destinations called
“1” and “4”, to represent them. The destination operator group of type 1 receives all the process
instructions & requested process messages well arranged on an ABAP based sheet or screen called
as a PI-Sheet (one for an order, for a destination). Whereas for a destination of type 4, a sheet
containing all the process instructions and requesting process messages, well arranged on a web
based sheet browser based PI-Sheet is sent to the internal operator/operator group.
   Note: An ABAP based PISHEET is shown below, if the same is set for a destination type 4 –
browser based PI-Sheet, then the sheet with the information would appear in a browser in HTML
format. With Destination type there are standard BAPI’s and connections working, which would
process the messages once sent back to SAP by the respective destinations.
  
Note: In configuration for the destinations of type 2 and 3, you can assign process instructions which
would be automatically become a part of control recipe and would be downloaded to the external
 control system. Whereas for destinations of type 1 and 4, there is a provision to assign the process
instructions in a sequence (making a list of suitable instructions) which are generated in the process
order control recipe and subsequently downloaded to the SAP operator/operator group.  
 
Note: Transaction to create the Control Recipe destination is O10C.
 
 
ABAP Based PISHEET

Order Information

Process order number 10002569

Process order type PI01
Plant 0002
Process order Quantity 10
Control Recipe number 100000000029823
Reservation Number 561543
Destination 01 – Shop Plant 0002
Date/Time 25th Dec 2010
 
Operation/Phase Information

Operation Phase Description Standard Start Date & Finish Date Destination
Values for the Time & Time
order

0010 0011   2 HR 25.12.2010 25.12.2010 01

12:45:00 14:45:00

0010 0012   1 HR 25.12.2010 25.12.2010 01

14:45:00 15:45:00

0020 0014   0.5 HR 25.12.2010 25.12.2010 01

15:45:00 16:15:00

Component Information

Operation Phase Component Description Qty UOM SLOC Batch

0010 0011 C1 C1 10 EA RM 0000000123

0010 0012 C2 C2 20 EA RM 0000000543

0020 0014 C3 C3 10 EA RM 0000000213

Requesting Phase Confirmations

Operation Phase Yield Scrap Set up Machine Text Reason

Time Time

               

               
               

Requesting Goods Issues

Component Qty UOM SLOC Batch Component Text Reason

Description

C1   C1          

C2   C2          

C3   C3          

Requesting Goods Receipts

Dynamic Function Call for MIGO_GR Transaction Code – Press here to access MB31 T - code

 
Control Recipe Destinations Type 2 & 3 - Destination outside of SAP (External Systems)
 
For control recipe destinations lying outside of the SAP system, i.e., external process control systems
or manufacturing execution systems lying outside of SAP, the process instructions are sent their
through a standard designed interface. There are majorly two control recipe destinations interacting
with external process control systems, namely “2” and “3”.
 
Destination type “2” is used when the SAP initiates the transfer or download of control recipe to the
external process control system (Push case); whereas “3” is used when the transfer or download of
control recipe is triggered by the external control system (Pull case).
 
Note - When the process control system is an external system, you can assign the process
instruction categories and have the system generate control recipes automatically.  
 
Note: In configuration for the destinations of type 2 and 3, you can assign process instructions which
would be automatically become a part of control recipe and would be downloaded to the external
control system. Whereas for destinations of type 1 and 4, there is a provision to assign the process
instructions in a sequence (making a list of suitable instructions) which are generated in the process
order control recipe and subsequently downloaded to the SAP operator/operator group. 
 
Note – For external control systems, it is required to define a RFC destination, so as to define the
connections to the control system and enable SAP to communicate with the system. The transaction
code to create is SM59.
 
 Figure 2
 

 
 Figure 3