SAP PP Master Data

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 PP Master Data

PP View’s of Material Master (MRP1, MRP2, MRP3, MRP4, and

Work Scheduling View)

Work Center

Routing

BOM

Production Version

Product cost collector (For Repetitive Only)

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Master Data Discrete Process Repetitive
Manufacturing Manufacturing Manufacturing

Work Center TCODE CR01 Known as TCODE CR01

Resource.
TCODE CRC1
BOM TCODE CS01 BOM & TCODE CS01
Production
Version created
and edited
directly from
within the
master recipe
Routing TCODE CA01 Known as Known as Rate
Master Recipe Routing.
TCODE C201 TCODE CA21

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Structure of Material Master

 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 the data.

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Structure of Material Master

In Material Master data is defined @ Client, Plant, Storage location level.

Important tables MARA, MARC, MARD

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Units of Measure
Base Unit of measure will be assigned to every material master. This is referred to as stock keeping
unit or smallest unit of measure used by material. This field is used across all clients and impacts all
plants of any company code. This is defined @ table MARA

Alternative unit of measure: In addition to base unit of measure that system uses for stock keeping all
other concerned departments can use their own units of measure.

Base unit of measure (Basic data 1)

Order Unit (Purchasing)
Sales Unit (Sales: Sales Org. Data1)
Production Unit( Work Scheduling)

All other units of measure are converted to the base unit of measure. If there is no standard formula
to convert an alternative unit of measure, you must enter the conversion factor for units of measure in
material master conversion.

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Create Material Master record for production planning material Sample Scenario
Show how to set default:

Industry sector
Material Master Views
Organizational levels
Default Views:

Basic Data 1
MRP1
MRP2
MRP3
MRP4
Work
Scheduling
Accounting 1
Costing 1

Material master records are grouped
together according to Industry sector and
material type. Industry sector defines
which Industry specific data should
appear in material master record. Material
type will define which process will be
allowed for material like production, sales,
purchasing and which further will decide
which functions allowed for material like
BOM creation
MRP Groups and MRP Profiles will make data entry easy for Material
Master
MRP Groups will be created in SPRO – Production – MRP – Master
data – create MRP groups (Assigned in MRP1).
Difference: MRP Groups and MRP profile: MRP Groups data will not
appear in material master
MRP Profile: Production – Master data – Profile – MRP Profile (TCODE –
MMD1)
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Create Material Master record for production planning material Sample Scenario

View Field Data

Entry Screen T-F##
Material Type Finish Product
Basic Data 1 Material description Rotary Pump GR##
Base Unit of Measure PC
MRP1 MRP Type PD
MRP Controller 000
Lot Size EX
MRP2 In house production 1
Schedule margin key 001
MRP3 Strategy group 10
Accounting 1 Valuation class 7920 Finish Product
Price control S
Standard Price 10

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BOM (Bill of Material)

BOM Categories

Single Level BOM

Alternative BOM
Multi Level BOM
Group BOM
Super BOM

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Create a Bill of Material

Base unit of measure for Item will be either unit

from Basic Data 1 View or it will be from unit of
issue maintained @ work scheduling view

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BOM Header

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 Item Details

A co-product is a product that is produced during the production of the main header material,
but has an appreciable selling price in the market. It is entered as Stock item in the BOM.

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 Item Category in BOM

Item Category: Each BOM item have an item category assigned to it. The item category defines the
features and functions of an item. Item category defines

Whether it is required to enter material against item category in item

Does item category supports qty based inventory management
Are both plus, minus signs supported for item

Item Category Description

N Non-Stock Items
R Variable size item (Cutting Bar to size)
K Class Item (Variant configuration)
D Document Item (DMS)
L Stock Items

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BOM Low Level Code

When you create BOM, system automatically assigns a low level code
to each material that MRP and costing use. This low level code will be
displayed in material master record.

The low level codes have the following key figures and uses:
They are used in MRP to determine the sequence in which
materials are planned.
They are used by product costing
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 Concept of Group BOM

Plant 1000

Group BOM
Plant 1100
Internal BOM No 1234
Plant 1200

Plant 1300

Plant 1400

Plant 1500

Plant 1600

Group BOM is a BOM which is without reference to any one plant. This is
useful for example, when engineer or designer is maintaining a BOM in
the engineering or designing phase. To make group BOM effective for
individual plants, we use plant assignment function. TCODE CS07 will be
used for plant assignment.

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 ECM to change BOM

Component replacements are common in your business. Therefore you need to use ECM to
plan the replacement of components well ahead of time. BOM reflects or triggers these
changes @ appropriate date.

Benefits of ECM:
Monitoring and documenting changes
Planning and executing changes @ specific point in time

Steps to Use ECM:

Create ECM no using TCODE CC01

Use this no in TCODE CS02 to change BOM

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Work Centers

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 Work Centers

Work Center Data

Name and Description

Basic Data Standard value Key

Default Values Control Key

for routing Standard text Key

Available capacity
Capacity data Formula Keys

Scheduling Formula key for

data scheduling

Cost Center
Costing data Activity types
Formula Key

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 Work Centers

Standard Value Key: Standard Values represent the times to be measured when work
center is used in a task list for example machine time, labor time and setup time. These
times are grouped together using standard value key. This key determines which values
are displayed for work center at the time of operation confirmation.

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 Capacity Categories and Capacity Header

A Major function of Work centers is to support capacity planning and scheduling. To plan these
functions, available capacity categories needs to be maintained in the work center. We can plan
as many as capacity categories under capacity tab of work center. But only first capacity
category will be considered while scheduling operation.

To plan individual capacities in

Capacity categories more details, you can define
capacity category header.
Energy
Factory calendar ID
Waste Base Unit of measure
Machine Start and Finish time
Length of breaks
Transport Capacity utilization in
Labor percentage
No of individual
Storage capacities
Planning details

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 Capacity Header

As of SAP R/3, Capacity data is a stand alone item of master data known as capacity header.
Each work center can have one or more capacity headers to describe its work limits with
regard to time. For capacity headers to function, you need to assign them to a work center. In
SAP ERP, capacities are created without reference to work center, when a reference capacity
or a pooled capacity is modeled.

Pooled Capacity: You use pooled capacity to model manufacturing resources that will be
shared by many work centers. Pool capacity makes sense only when capacity is actually
constraint.
Example: You have 5 production lines, each of which requires an operator for entire duration
for which machine runs. However you only have 4 operators in your resource pool. Therefore
only 4 machines can run at any given time.
Here we can plan for pooled capacity.

Reference Capacity: Reference capacity will reduce our data entry efforts. For example Our
work Center is group of technicians and every one in group is assigned with pneumatic gun.
Now we can create capacity header (category machine: pneumatic gun) as reference capacity.
This will reduce our data entry efforts.

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 Create Work Center

Field Value
Basic Data
Plant 1000
Work Center KTM100 Field Value
Work Center 0003 Description KTM 100 Machining Center
Category Person Res 000
Usage 009 All task lists
Default Values Std Value Key SAP1
Rules for maint Setup should, Machine Must,
Field Value Labor No checking
Control PP01-PP99 Key of Machine -090%
Key Performance
Unit Min
Ref Ind Select this check
box for control key

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 Create Work Center

Capacity Tab Scheduling Tab

Field Value Field Value

Capacity 001 Capacity category 001
Category Setup Formula SAP001
Setup Formula SAP005 Processing Formula SAP002
Processing SAP006 Queue Time 2 hr
Formula
Capacity Planner 000
gr
Costing Tab
Factory Calendar 01
Base unit HR Field Value

Start time Cost 4230

Center
Finish Time
Activity Setup 1422, M/c 1420
Length of Breaks 1 type
Capacity uti 90% Formula Setup SAP005, M/C SAP006
No of Indiv. Cap 2 Key
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 PP Work Center and Costing

Cost center assignment to Work Center for operation costing

Work Center

Cost center with

Activity Activity types
rates are
maintained Setup
in KP26
Machine Activity Types
Labor

Routing Operation Work Center

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 PP Master Data Task List

Task List type Indicator Application

Routing N Discrete manufacturing
Reference operation sets S Discrete manufacturing
Rate Routing R Repetitive manufacturing
Reference rate routing M Repetitive manufacturing
Master Recipe 2 Process manufacturing
Inspection Plan Q Quality management

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 PP Routing structure

Routing with or Without

Material Reference

Routing Group @ More than one task list

Material Plant under Group will increase
combination Group counter

Sequence Standard,
Alternative, Parallel

Operation 10
Operation 20
Assignments: Operation 30
Material Components
PRT’s Operation 40
Inspection Characteristics
Trigger Points

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 PP Routing Material Assignment
and Component Assignment

Material Allocation:
Create Routing for Specific material

Use Material assignment function in

routing header

Use of Production Version

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Create Simple Routing: Initial screen

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Operation Overview

Component Allocation

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 Parallel and Alternative Sequence in Routing

Alt Sequence # 1 Std Alt Sequence # 2

OPE 10 Sequence OPE 001
OPE 200 OPE 10
OPE 002
OPE 300 OPE 20
OPE 003
OPE 004 OPE 30
OPE 004

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 Create simple Routing

Create a simple routing for the production of material T-B** in plant 1000 that consists of the four steps in the
table below. Routing status should be creation phase, valid from today’s date with production usage and for lot
size from 1 to 100,000 pc. Use following primary operation data

Operation # Work Center Control Key Description

10 T-A** PP01 Lathe casing
according to drawing
20 T-B** PP01 Drill holes
30 T-C** PP01 Insert gasket
40 T-C** PP01 Inspect & deliver to
stock

Use the following standard processing times

Activity OP 10 OP 20 OP 30 OP 40
Setup 10 Min 3 Min 0 Min 0 Min
Machine 30 Min 10 Min 0 Min 0 Min
Labor 30 Min 10 Min 5 Min 10 Min
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Thank You

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