Cable - Make to Order (Main Scenario)

Purpose
This scenario shows a complete make to order business scenario for Long Products Planning (LPP) including sales order entry, production and scheduling, delivery and billing. Long products must be planned and produced on the basis of individual lengths and not on the basis of aggregated quantities. Physically long products cant be simply joined together. To cover requirements you can either produce them or (if allowed) you can cut longer supply elements. To cover a requirement of 1000 m you cant fulfill with 1000 pieces (each with 1 m) or any other valid combination. You can fulfill this requirement only by delivery of ONE length with 1000 m (within tolerances)

System Landscape
System Landscape, this Process is built in SAP for Mill Products => find system: IDES System Landscape Viewer

Solution Components used in this Process Enterprise Portal ERP SCM

Users
The scenario can be run with a predefined user ID. This is an option if you dont want to create an individual ID via self-service in SAPNET. The following data can be used to log on: Predefined User (Role) MILL_DEMO MILL_DEMO MILL_DEMO Password welcome welcome welcome 720 720 Client Component Enterprise Portal ERP SCM

If a scenario needs a special user ID it is mentioned in the scenario documentation script.

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Data Used During this Process

Field Company code Sales Organization Distribution Channel Division Plant Shipping Point Storage Location Material Number Material Number Data - America Data - Europe M100 M110 01 M1 M110 M110 M110 MK_APO_F100 MK_APO_S100 Finished product Semi Finished product Description

Process Flow
1. Post Goods Receipt for Finished Good 2. Create Sales Order 3. Post Goods Receipt for Components 4. Create Production Order 5. Display Stock/Requirements List 6. Release Production Order 7. Goods Issue for Components 8. Order Confirmation 9. Goods Receipt and Batch Creation for Production Order 10. Create Delivery 11. Delivery-Related Trading Unit Change (DTUC) -Processing Delivery 12. Change Delivery and Post Goods Issue 13. Billing/Transfer to FI/CO See also the IDES Scenario Cable Cutting for an stand alone manual cutting process.

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Main scenario: The scenario starts with creation of Sales order with 3 x 2000m cable length = 6000m total item quantity. The first length will be fulfilled by a batch on stock with 1 x 2050m, cause per individual length a length tolerance of plus 10 % is allowed. The second length will be fulfilled by cutting 1 x 2000m from a batch with 1 x 3000m. The 3rd length has to be produced. The production order with 1 x 2000m is created by converting the planned order. In production order the needed component batches are selected by batch determination. Before, you have to post goods receipt for the component batches. After posting goods receipt of finish product, the delivery is created. The APO had allocated the batch with 1 x 2050m, the batch with 1 x 3000m for cutting process and the 1 x 2000m which we produced. The cutting is done by function delivery dependent trading unit change (DTUC). After confirmation of cutting, a new batch number is automatically created and updated into batch split item of delivery.

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Procedure
Post Goods Receipt for Finished Good
1. Log on to the ERP system with user ID MILL_DEMO and password welcome. 2. In the ERP system, choose Logistics Materials Management Inventory Management Goods Movement Goods Movement (MIGO). Or use transaction code MIGO. 3. Enter the following data: Field Action Reference Document Receipt w/o PO 4. On tab strip Material enter the following data: Field Material 5. Choose tab strip Quantity. 6. Enter the following data: Field Quantity EUn 7. Choose tab strip Where. Field Plant Storage Location Data US Data EU M110 M110 . Data US Data EU 2050 M Data US Data EU MK_APO_F100 Data US Data EU Goods Receipt Other 501

8. To enter a second line item with different quantity/ cable length choose 9. Enter the following data: Field Plant Storage Location 10. Chose tab strip Material. 11. Enter the following data: Field Material 12. Choose tab strip Quantity. 13. Enter the following data: Data US Data US

Data EU M110 M110

Data EU MK_APO_F100

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Field Quantity EUn 14. Choose .

Data US

Data EU 3000 M

15. Choose Check. The system creates two batch numbers. 16. To confirm the dialog box, choose 17. Choose . .

Please check the stock situation with transaction MMBE. If you find some other batches with different length, this example data does not match. Each length between 2200 m (2000 + 10 % plus tolerance) and 4000 m is fine. As soon you enter 4000 m, no planned order is created, because you can cut 2 x 2000 m.

Create Sales Order

1. Choose Logistics Sales and Distribution Sales Order Create. Or use transaction code VA01. 2. In the Create Sales Order: Initial Screen enter following data: Field Order Type Sales Organization Distribution Channel Division 3. Choose Field Sold-to party Purch.order no. . Data US Data EU MK-CUST101 Any Data US Data EU MKOR M110 01 M1

4. In the Create Mill Standard Order: Overview screen enter:

5. In the Create Mill Standard Order: Overview screen choose tab strip Fast data entry (if not defaulted) and select: Field Char display Data US Data EU Cable Sales

The table control display changed. You see now additional columns to enter. These are the variant configuration characteristics. 6. Enter the following data (without using ENTER, move forward with TAB key).

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Field Material Order quantity Factor Individual Length Overdelivery Tolerance (%)

Data US

Data EU MK_APO_F100 (no entry needed, will be calculated) 3 2000 10

If you enter in the characteristics Overdelivery Tolerance different values, the example scenario could have other results. It depends mainly on the quantity (=length) of batches in stock.

The calculation of the tolerance range is done by coding from OSS note 873068. The coding fills the batch search characteristics with the range 2000 2200. This range is transfered to APO later. 7. Choose .

The system displays the Process Selection Criteria dialog box, with the calculated selection range of the Individual length 2000 2200 m. If the box is not displayed, choose . 8. Choose .

The data is transferred to the SAP APO and an availability check is triggered. 9. On the APO availability check: Delivery proposal screen you see following:

2 x 2000m could be fulfilled from stock, 2000m must be produced. 10. Note the confirmed dates for the line items. 11. Choose Full delivery. 12. Select line item 10 and choose .

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13. Choose tab strip Shipping. 14. Enter total quantity tolerance: Field Overdeliv. Tolerance Data US Data EU 10

Dont save the Sales Document for now, if you like to continue with the Jumping Points.

Jumping point
Scenario Cable - Fast Data Entry SD Scenario Cable - Pricing Based on Characteristics Scenario Cable - Customer Material Info record

Coming back from the jumping points you should have just the one line item in your sales order youve created before. Delete all others, except of item 10. 15. Choose .

16. Note your sales order number.

Post Goods Receipt for Components

1. In the ERP system, choose Logistics Materials Management Inventory Management Goods Movement Goods Movement (MIGO). Or use transaction code MIGO. 2. Enter the following data: Field Action Reference Document Receipt w/o PO 3. Choose tab strip Material. 4. Enter the following data: Field Material 5. Choose tab strip Where. 6. Enter following data: Field Plant Storage Location 7. Choose 8. Choose . . Page 7 of 16 Data US Data EU M110 M110 Data US Data EU MK_APO_S100 Data US Data EU Goods Receipt Other 501

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9. In the Distribute Quantity dialog box enter the following data: Field Qty in UnE (1st item) Qty in UnE (2 item) 10. Choose Adopt.
nd

Data US

Data EU 2023 2023

The system creates two items. 11. Choose tap strip Batch. 12. Enter the following data: Field Batch 13. To maintain the second line choose 14. Enter the following data: Field Batch 15. Choose Check. 16. Choose . Data Your initials ## (different from the batch number from above) . Data Your initials ##

Because the material is defined in material master as single unit batch managed, the quantity of the batch is equal to the length of the batch. The quantity is automatically written into the characteristic Ind. Length in Base UoM ="M (Characteristic SAP_MILLCA_LENGTH_SUB). There is a second characteristic Individual length (SAP_MILLCA_LENGTH), which is relevant for APO. The content is copied from SAP_MILLCA_LENGTH_SUB at time of posting goods receipt.

Create Production Order

1. In the SCM choose Advanced Planning and Optimization Production Planning Interactive Production Planning Product View. Or use transaction code /SAPAPO/RRP3. 2. In the Product View screen enter following data: Field Plng Version Product Location 3. Choose . Data US Data EU 000 MK_APO_F100 M110

APO displays your sales order (2 x 2000m) and the automatically created Planned Order with 1 x 2000m (1 x 2050m is allocated from stock). 4. Choose .

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Jumping point
Scenario Cable - Display Characteristic Values in APO Product View 5. Set the Conversion indicator of the Planned Order (2 columns right of the green characteristic triangle). 6. Choose .

The Product Availability Overview screen displays that the number for missing parts is 0. 7. Choose 8. Choose . until your planned order was converted to a production order (PrdOrd (C)).

9. Note the production order number.

Display Stock/Requirements List

1. In the ERP system choose Logistics Production MRP Evaluations Stock/Requirements List. Or use transaction code MD04. 2. Enter the following data: Field Material Plant 3. Choose . Data US Data EU MK_APO_F100 M110

The system displays your sales order and the corresponding production order. 4. Double-click on the production order number. 5. Choose . .

6. To display the component overview choose

You see for components MK_APO_S100 the quantity 2020 m each. Because 1000m length of finish product needs 2 components with 1010m each, the total result for 1 x 2000 m = 2000m needs 2 items with 2020m each.

Release Production Order

1. In the ERP system choose Logistics Production Shop Floor Control Order Change. Or use transaction code CO02. 2. Enter the following data: Field Production Order 3. Choose 4. Choose . . Data Your noted production order number

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5. Select item 0010 and choose

6. Select one of your created batches (Your initials ##). 7. Note the batch number you have chosen. 8. Choose Copy.

Only component item 0010 will be issued in this example. 9. Choose 10. Choose . .

Goods Issue for Components

1. In the ERP system, choose Logistics Materials Management Inventory Management Goods Movement Goods Issue (MIGO). Or use transaction code MIGO_GI. 2. Enter the following data: Field Action Reference Document Order 3. Choose Field Item OK 5. Choose tap strip Batch. 6. Position the cursor on field Batch and choose 7. Choose tab strip Batches for material. 8. Select the batch which you have not chosen in the production order (Your initials ##). 9. Choose . . . Data X Data Goods Issue Order Your noted production order number

4. Enter following data:

10. In column Line click on 3. The field Batch is already filled with the batch from the production order. 11. Enter following data: Field Item OK 12. In column Line click on 2. 13. Enter following data: Field Item OK 14. Choose tap strip Where. SAP Demo Systems Page 10 of 16 Data X Data X

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15. Enter following data: Field Storage Location 16. Choose Check. 17. Choose . Data US Data EU M110

Order Confirmation
1. In the ERP system choose Logistics Production Shop Floor Control Confirmation Enter For Order. Or use transaction code CO15. 2. Enter the following data: Field Production Order 3. Choose . Data Your noted production order number

By using the button Goods movements on the confirmation screen you could do the goods issue for the components (and run a batch determination for the components) if youd like to do the confirmation and goods issue in one step. If you use this possibility dont do the goods issue as described above. Back flushing must be set in configuration of the bill of material in order to run the goods movement automatically. 4. Enter the following data: Field Yield to confirm Confirmed scrap 5. Choose . Data 2000 (as proposed in column Total to confirm) 0 (as proposed in column Total to confirm)

Goods Receipt and Batch Creation for Production Order

1. In the ERP system choose Logistics Materials Management Inventory Management Goods Movement Goods Receipt GR For Order (MIGO). Or use transaction code MIGO_GO. 2. Enter the following data: Field Action Reference Document Order 3. Choose . Data Goods Receipt Order Your noted production order number

4. Enter the following data: SAP Demo Systems Page 11 of 16

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Field Char. display 5. Choose tap strip Quantity. 6. Enter the following data: Field Qty in unit of entry Item OK 7. Choose tab strip Batch. 8. Enter the following data: Field Batch 9. Choose Check.

Data Cable PP order confirmation

Data 2000 (as confirmed quantity without scrap) X

Data Your initials ##

The system creates a batch. Characteristics are copied from the configuration. 10. Choose Classification. Verify characteristic length Value is proposed by production order valuation. 11. Choose 12. Choose . .

One line with value 2000 is available.

I.e. if quantity would be 10000 m and characteristic length would be 1000 then you would have in this screen 10 lines proposed each with 1000 quantity and value for characteristic length with 1000. This screen offers you also possibility to maintain additional characteristics in an easy way. 13. Choose 14. Choose . Copy.

Create Delivery
First step of the delivery processing is the delivery creation. To create a single delivery for a special order the order number must be known. The finished material is in unrestricted stock. The availability check for the delivery item is carried out, the batch(es) are assigned automatically. 1. In the ERP system choose Logistics Logistics Execution Outbound Process Goods Issue for Outbound Delivery Outbound Delivery Create Single Document With Reference to Sales Order. Or use transaction code VL01N. 2. On the Create Outbound Delivery with Order Reference screen enter following data: Field Shipping Point Selection date Order Data US Data EU M110 1 month in future Your noted sales order number

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3. Choose

The system displays the Message Packing not possible due to DTUC status.

Batches which are assigned by batch determination based on SCM system information must first be cut to required lengths specified in sales order. (DTUC process) 4. To display details, choose tab strip Status Overview. 5. To look at details, choose . 6. In table Overall status Delivery in column DTUC verify DTUC status B Partially processed. 7. In table delivery item status (all items) verify DTUC status in column DTUC. Two items have DTUC status C, one item for the batch with 3000 M the DTUC status is A. 8. Note the item number with status A. 9. Choose tab strip Item Overview. The system displays the delivery item with total amount of 6050 M. 10. To see the batch structure, choose . The 2050 M batch which is available from unrestricted stock and the produced 2000 M batch was automatically assigned by functionality batch determination (based on pegging information from SCM system). The 3rd batch with 3000 M has to be cut to 2000 M. 11. Choose 12. Select item 10 and choose Batch split.

The system displays the batch numbers. 13. Choose Batch determination, you see following result.

14. Choose 15. Choose

. Batch determination.

Now you are back to the Batch determination SD: Select batches screen and the column split quantity is editable. For example you can set the quantity to 0. 16. Choose Selection Criteria. 17. Choose .

You can see, that no change of the selection criteria is allowed, because the selection criteria from SD order are relevant. SAP Demo Systems Page 13 of 16

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Other batch numbers are displayed and can be selected manually, if they are within the range of SD order batch selection criteria. (tolerance) 18. Choose 19. Choose 20. Choose . . .

21. Note your outbound delivery number.

Delivery-Related Trading Unit Change (DTUC) Processing Delivery

Cutting can be done in reference to sales, but also manual, in reference to users decision. Goto Demo scenario scenario Cable cutting, if you like to understand the manual process. Batches which are assigned to delivery by SCM system must be cut before the delivery could be finished (i.e. post goods issue for delivery). You have first to cut to required lengths (which are specified in sales order). In this scenario cutting will be executed by usage of Delivery-Related Trading Unit Change (DTUC) functionality. 1. In the ERP system choose Logistics Sales and Distribution Shipping and Transportation Delivery-Related Trading Unit Change. Or use transaction code MILL_CUT_LBA. 2. Enter the following data: Field Action Reference Document Delivery Item 3. Choose . Data DTUC Processing Delivery Your noted delivery number Your noted item number with DTUC status A

4. To confirm the Automatic batch number allocation dialog box choose Yes. 5. Enter the following data: Field Char. Display Data Cable MIGO

By this functionality you would be able to valuate characteristics before posting batches (not necessary in this scenario) in table Receiving Items. It is not necessary to maintain characteristic Individual Length. 6. Select in the field Remaining Qty. the setting Remainder stays in issuing batch. 7. Choose Check. 8. Choose .

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Change Delivery and Post Goods Issue

Now after finishing DTUC process second batch is also matching sales order requirements with regard in this example to characteristic Individual Length. Delivery processing can go on. 1. In the ERP system choose Logistics Logistics Execution Sales and Distribution Shipping and Transportation Outbound Delivery Change Single Document. Or use transaction code VL02N. 2. On the Change Outbound Delivery screen enter the following data: Field Delivery 3. Choose . Data Your noted delivery number

Message Packing not possible due to DTUC status will no longer appear. 4. To display details, choose the tab-strip Status Overview. In table Overall Status Delivery in column DTUC verify status C (Completely processed) DTUC status. 5. Choose . Verify DTUC status in column DTUC (most right one) in table delivery item status (all items). 6. Choose tab strip Picking. 7. Choose . The system displays the delivery items. 8. Enter following data: Field Pick Quantity (next to the 1 batch number) Pick Quantity (next to the 2nd batch number) Pick Quantity (next to the 3 batch number)
rd st

Data 2000 2050 2000

Jumping point
Scenario Cable - Pricing in Deliveries 9. Choose Post Goods Issue. 10. If necessary to confirm warnings choose .

In the mill industry normally the customer dont get exactly the ordered quantity delivered, if he has ordered in e.g. LB (KG) or INCH (M). The reason is, that just integer quantities in PCs can be delivered. For this reason the under- and over delivery tolerances in the mill industry should be greater than in other industries. If the delivered quantity is within these tolerances the open remained quantity of the delivery will be set to 0.

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Billing/Transfer to FI/CO
1. In the ERP system choose Logistics Sales and Distribution Billing Billing Document Create. Or use transaction code VF01. 2. Enter the following data: Field Document 3. Choose . Data Your delivery number is defaulted

On the Invoice (F2) Create: Overview of Billing Items screen a line item for each batch is generated to take over the correct weights. If you have entered or changed some freight conditions during delivery processing they are copied into the billing document. To show them branch into the condition overview by choosing . 4. Choose .

All postings in accounting are done at the same time in background.

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