6 - SAP - PP Level I Training

Honda-Goa, 06th May 2009
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SAP PP MODULE

Presented By :
Srinivas U.B

LEVEL 1 TRAINING AGENDA
SAP Overview (Structure and Modules)

SAP Implementation Methodology

PP Module overview
LEVEL 1 TRAINING
SAP

Systems Application and Products
In Data Processing
Before SAP Implementation
Sales
Manufacturing
Human
Resources
Finance
Controlling
Purchasing
Reconciliation
Reconciliation
After SAP Implementation
Finance
Materials
Management
Controlling
Sales &
Distribution
Human
Resources
Production Planning
SAP
SAP
SAP
SAP
SAP
SAP
SAP
SAP
SAP
server
During Project
Preparation, project
guidelines and teams are
established, project scope
and strategies are refined.
Our project team will be
briefed and mobilized with
a kick-off meeting
During Realization,
business and process
requirements based on the
Business Blueprint are
configured and implemented.
The SAP R/3 system in this
phase would have gone
through thorough unit and
integration testing and is
ready for the Final
Preparation
During Final Preparation, final
acceptance sign-off would have been
gained from stakeholders and cutover
readiness and cutover readiness
check is completed. The SAP R/3
system and the organization is ready
for Go-Live
During Business Blueprint,
the as-is and to-be business
requirements are documented as the
baseline of how the key business
processes will be configured and run
within the SAP R/3 system
During Go-Live & Support,
the SAP R/3 system is live. The
project team along with DC
consultants will support the end
users to ensure familiarity to operate
the new system as per the business
processes
0
The project implementation stages will be described as followed
3A
During Parallel Test, the user
will enter transactions in legacy and
SAP systems. At the end of the
month, the results will be compared
to check the SAP system design
accuracy.
Parallel Test Run
Copyright 2009 Tata Technologies. All rights reserved. All other trademarks are trademarks of their respective owners.
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PP Master Data :
Material Master
Bill of Material
Work Center
Routing
Sales and Operations Planning

Demand Management
Long Term Planning
MRP
Planned order
Production Order
Back flushing
Production Order
Confirmation &
Settlement
SAP R/3 PP Module overview
Org. Structure
SAP R/3 Integration

Organizational Structure
Organizational Levels
Client
Company Code 1 Company Code 2
Plant 1 Plant 2
SLOC 2 SLOC 1
Controlling Area
P Org 1
SALES ORG
DISTR.
CHANNEL
DIVISION
SALES AREA
SLOC 2 SLOC 1
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Sales &
Distribution
Production
Planning
Materials
Management
Finance &
Controlling
Customer
Sales Order
Shipment
Receivable Accounts / Cash Receipt
Credit Limit
Material Availability Check
Transfer of Requirements
Goods Issue to SO
G
o
o
d
s

R
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p
t

I
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v
o
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e

R
e
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i
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t

P
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O
r
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e
r

Accounts Payable
Invoice
Accounting Document
Production Cost
Material Requirements
Material Procurement
Sales Order / Forecast / Plan
Vendor
Process Flow Integration
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Master Data
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PP Master Data
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Each user function has its own view of the material master which
permits easy access and maintenance of data.
MRP
Storage
Stocks in plant/
storage location
Costing
Accounting
Basic Data
The material master is a
central data object for all
material types:
raw materials
semi-finished products
finished products
P.R.T.
Purchasing
Sales
Work
scheduling
Quality
management
Classification
Forecasting
Views of the Material Master

15
Basic Data view
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MRP View
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Why is this view used?
To record data related to
production such as:
Units of issue
Issue Storage Location
In-house production
time
?
?
Which departments use this view?
Engineering
Shop Floor Production
Materials Management
Engineering
Shop Floor
Production
Materials
Management
Work Scheduling View
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View is used to record following
data
Shelf life data
Stock Determination
Profit Center
?
?
Which departments use this view?
Shop Floor
Materials Management
Shop Floor
Production
Materials
Management
Plant Data / Storage Views
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Bill of Material
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Bill of Material
A bill of material is a complete, formally structured
list of the components of a product or assembly.
A bill of material contains the description and
object number of each component, the quantity
and unit of measure.
BOM
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Multi Level - Bill of Material
Combining single-level BOMs
creates a complete multi-level
structure.
Machine
Fly wheel
Chain Frame Shaft
Assembly 1
Assembly 2
Motor Gear Exhaust
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Bill of Material Usage
BOM
Sales Data
Production
Data
Engineering
Data
Costing
Data
Different types of BOM usage;
Engineering
Production
Costing
Sales
BOM Item Status
Released
Blocked

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Bill of Material Structure
BOM header maintained with structure of assembly components & sub assembly items with respective
base quantity and unit of measure.
BOM status governs, whether the BOM is active or inactive.

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Work Center
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Work center
Definition
Examples
Type of work center Example

Individual work center Automatic lathe 17
Work center group Machine shop
Assembly line Line 9
Individual person John Doe
Group of people Group 12
Usage
Work centers are used in routings. They can also be used
as capacity collectors for statistical evaluations.
A work center is an organizational unit where
a work step (operation) is performed.
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Basic data
General data
Name and description
Standard value key

Default values
Standard values
for routing
Control key
Standard text key

Capacity
Capacity data
Available capacity
Formula key
Scheduling
Scheduling data
Scheduling basis
Queue and move times
Formula key
Assignment
Costing data
and
HR data
Cost center
Activity types

Work center Data
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Routing
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Routings
A routing contains the operations to be performed, their sequence and the
various work centers involved to manufacture an item.
ROUTING STRUCTURE
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Group
Counter 01
Group
Counter 03
Group
Counter 04
Routing Group
Each individual routing is referred to as a group counter within the group

Routings
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Routings contain:

Manufacturing In-house components & finished goods.
The work centres where the operations are to be performed

Material allocation
The manufacturing material is allocated to the group counter.
Component are allocated to operations and standard values for
Setup time,
Processing time
Tear-down time
Routings
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Demand Management
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Demand Management
Sales Plan Prodn Plan Forecast Plan
Demand Management
Demand Program
Manual Planned
Independent
Requirements
Sales
Demand from
Sales Orders
MRP/MPS
Demand mgmt will have product, qty & Rqd. Date
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Demand Management Process
Demand Management
Customer or sales requirements ( Export or Domestic).
Planned independent requirements.
Planning strategies
Methods of production for planning & manufacturing or procuring a
product.
Different planning strategies used are;
Make to stock
Make to order
Planning with final assembly

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MRP
Honda-Goa , 06th May 2009
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MRP Overview
SAP AG 1999
Complete MRP Overview
Planned
order
Dep. reqmts
Reservations
Purchase
requisitions
Production
order
Purchase
order
Schedule
lines
MRP MRP
Only for
materials procured
externally
Only for
materials procured
externally
Convert
Warehouse
Sales orders
Planned ind reqmts
Stores Stock
Stores Stock
Honda-Goa , 06th May 2009
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MRP- Stock Requirement List
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Production Control
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Production Methods
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Discrete manufacturing:
Frequently changing products
MFG restricted production lots
Varying sequence of work centers over which a product can run

Repetitive Manufacturing:
Same product is produced over a longer period of time in one
production line
Total quantity of the product is manufactured over a specific period of
time with a specific production rate per partial period

Production Methods
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Production Orders
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8 - Issue
Materials to
Order
1 - Select
BOM
2 - Select
Routing
3 Schedule Dates
(Fwd / Backward)
5 - Calculate
Capacity
Goods
Issue
6 - Calculate
Planned Costs
Release
Order
4 - Check
Availability
7 - Print Shop
Floor Papers
Create
Order
Confirm
Completion
9 - Receive complete
goods into stock
Goods
Receipt
10 - Calculate
Actual Costs
Actual
Labor
Confirmation Slip
Production Order Overview
Cost Release
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Production Order Settlement

A Production Order collects all costs associated with making an inventorial item and
the order picks up the cost from Material master.
Production cost analysis carried out after Final Confirmation & Order Settlement.
Bill
of
Material
Routing
Production Order
STATUS:
Created, Released,
Confirmed, Delivered,
Settled
Order: 73
Type: PP01
Plant: LR001
Sys Status:
CRT REL CNF DLV SETC

Quantities:
Total Produced: 100 Tons
Scrap: .001
Confirmed: 100 Tons
Dates:
Schedule 09/15/95
Confirmed 09/16/95
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Backflushing
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GR/GI will happen simultaneously at the time of Posting.

Backflushing Process
Hinjawadi , 06th May 2009
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THANK YOU

6 - SAP - PP Level I Training

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Honda-Goa, 06th May 2009

Views of the Material Master

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