Beruflich Dokumente
Kultur Dokumente
Agenda
Attendees:
Business Managers, Process Owners
Topics:
Master Data
Demand Management
Production Planning
Production Execution
Contents of Presentation
Demonstrate the planning/execution process
Discuss Company production process
Communicate scope expectations
BOM
WORK CENTER
The material master is a central data object in the SAP R/3 System.
All the information required to manage products and equipment is stored in the material
master record.
Each user department has its own view of the material master which permits easy access
to and maintenance of data.
Bill of Material
Motorcycle
Power Train
Motor
Gea
r
Exhaus
t
Chassis
Front
Whee
l
Rear
Whee
l
Fram
e
Brake
System
PRODUCT-1
ITEM - 1
VARIANT BOM
PRODUCT-2
ITEM - 1
MULTIPLE BOM
ITEM - 2
PRODUCT-1
ITEM - 2
PRODUCT-1
ITEM -2
ITEM - 1
ITEM - 2
Engineering
Production
order
Operations
Material
BOM
Costing
Technical data
Plant maintenance
Price
Location data
Order quantity
SAP AG
Work centres
Work centres are used to describe where work is performed.
Each work centre is defined by the machines or employees
involved in the production process.
Each work centre contains distinct capacity, costing, and
scheduling information.
Work centre 1
WC 5
WC 4
WC 2
WC 3
Work centre 6
Work Center
WORK CENTER IS A LOCATION WHERE A PARTICULAR
OPERATION IS EXECUTED
THE FOLLOWING CAN BE DEFINED AS WORK CENTERS :INDIVIDUAL WORK CENTER
WORK CENTER GROUP
PRODUCTION LINE
INDIVIDUAL PERSON
GROUP OF PERSON
AUTO LATHE NO : 10
LATHE SHOP
ASSY LINE NO: 1
MR.RAM
POOL OF 12
Task
Tasklists
lists
11
Costing
Costing
data
data
Scheduling
Scheduling data
data
and
and
Available
Available capacity
capacity
Costing
Costing
Lead
Lead time
time
scheduling
scheduling
Capacity
Capacity planning
planning
2724.00
2724.00
1200.00
1200.00
124.00
124.00
4048.00
4048.00
Basic scheduling
Data from the material master is used for scheduling
Finite scheduling
Data from the routing in addition to the existing load (on a day to day basis)
on the work center is used for scheduling
Approaches to Scheduling
Forward scheduling.
Scheduling type in which the operations an order are scheduled forward starting
the planned start date.
Backward scheduling.
Scheduling type in which the operations of an order are scheduled backward
starting from the planned finish date.
Today scheduling.
Today scheduling is forward scheduling starting from the current date.
Scheduling
Routings
Material
Routing
group
Operation 20
Operation 10
Work centre
Texts
Control data
Times
Material
components
PRT
For each operation, the material components and the production resources and tools
required to produce the material are maintained in the routing.
B
Material
Routing
Bill
Billof
ofmaterial
material
Op. 10
Item 10
Op. 20
Item 20
Op. 30
Customer
Customer
Order
Order Mgmt
Mgmt
SOP
Forecasting
Sales &
Operations
Planning
MPS
Demand
Management
Demand
Management
MPS
Capacity
Capacity
Production
ProductionMaster
MasterData
Data
Reporting
Reportingand
andAnalysis
Analysis
MRP
MRP
EXECUTION
Manufacturing
Execution
Order
Settlement
Inventory
Inventory
Costing
Costing
Manufacturing Planning
Manufacturing Planning is the process of using
forecasts and customer demand to create
production and procurement schedules for finished
products and component materials.
Demand Management
DEMAND MANAGEMENT
Demand
Demand program
program
MPS or MRP
Demand management determines the requirement dates and quantities for important
assemblies and specifies the strategies for planning and producing or procuring finished
products.
Make to Order
Sales
Order
M.R.P.
M.R.P.
C.R.P.
C.R.P.
Production
Production
Execution
Execution
Sales
Sales Order
Order
Stock
Stock
The cycle can not start till we get any sales order.
After we get the sales order for the final product dependent
requirements are generated through M.R.P.
After the production execution the stock produced is for that particular
order, it can not be shared by any other order.
Make to stock
Forecast
M.R.P.
M.R.P.
C.R.P.
C.R.P.
Production
Production
Execution
Execution
warehouse
warehouse
Stock
Stock
Planning
Planning
Production
Production
Sales
Sales order
order
Customer
Customer
Requirement
Requirement
Consumption Process
Comparison
Comparison with
with
planning
planning quantities
quantities
Forecast
Forecast
Total
Total
Requirements
Requirements
Master
Master Plan
Plan
Planning
Planning quantities
Customer requirements
Features:
Planning is done at the finished product level
Procurement and production are initiated after the planning stage
Sales orders consume planning quantities
Planned quantities that are not used increase warehouse stock
Additional requirements automatically adjust demand program
Availability check is based on available-to-promise (ATP) logic.
Use the independent requirements from Demand Management plan to create the Master Production
plan.
Master Production Scheduling (MPS) creates planned order proposals for each master schedule item
and generates the dependent requirements for the first-level components in each products bill of
material.
The master planners review and update the suggested master production schedule before generating
a detailed production schedule.
In material requirements planning (MRP), the system calculates the net requirements
while considering available stock and scheduled receipts from purchasing and
production.
PROCUREMENT SPECIFICATION
SCHEDULING
BOM EXPLOSION
Consumptionbased planning
MRP
Forecast-based
planning
Reorder point
planning
Automatic
reorder point
Manual
reorder point
Consumption-based planning
Manual reorder point planning
Automatic reorder point planning
Forecast-based planning
Reorder
level
Safety stock
Reorder
point
No materials planning
Delivery date
Time
Planning Result
Planning
Planned
Order
MRP
Purchase
Requisition
Execution
Production
Order
Order
Release
Goods
Issue
Completion
Confirmation
Goods
Receipt
Order
Settlement
Production
Order
Availability check
Order release
Printing
Printing of
of
documents
documents
Material
Material
withdrawal
withdrawal
Completion
Completion
Processing
Processing confirmation
confirmation
Goods
Goods
receipt
receipt
Order
Order
Settlement
Settlement
Manufacturing Execution
Initiate Manufacturing Execution by releasing each production order to the shop floor.
The material handlers pick the appropriate quantities of component materials and
perform the necessary inventory transactions.
The production and assembly operations are performed, labour is reported, and the
completed product is received into stock.
The stock values are updated in the material master records and
the stock/consumption accounts are updated in the General
Ledger.
Completion Confirmation
A completion confirmation documents the processing status of
operations. As such, completion confirmations are used to
monitor the progress of production orders.
A completion confirmation is used to record:
Goods Receipts
Order Settlement
During confirmations, the actual hours performed, quantities produced, and costs
incurred are confirmed.
The plant cost analyst then closes the production order and settles any cost
balances and variances (if any) to the appropriate financial accounts.
2 Weeks
(ending
July 23)
6 Weeks
(ending
Sep 03)
12 Weeks
(ending
Nov 30)
4 Weeks
(ending
Dec 31)