Production Planning

SAP PP Books

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Production Plannning and Control with SAP

SAP MM / PP Interview Questions, Answers,
and Explanations: SAP Production Planning Certification

more Books on SAP Production Planning

Hierarchical Structure of the Project definition

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Hierarchical Structure of the Project definition

A few Definitions of the terminologies used in the above diagram:

Project:

The project definition is the binding framework for all organizational elements within a project.

Work Break down Structure:

With a work breakdown structure you can divide the project into useful steps, specify fixed or
"basic" dates, specify the work involved, and determine project costs. The individual levels of
the hierarchy in a work breakdown structure enable you to organize a project into steps.

Work Break down Structure Element (Sub WBS):

You can further break down these steps into individual elements. Maximum steps supported
are 99.

Network:

It is a special type work order on which cost can be planned, controlled and monitored.

Activities:

These are the actual tasks that are to be executed for the completion of the project.

PP Help Tutorials(pdf)

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Production Planning materials from SAP Help

Production Order Splitting

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Production Order could be split due to following reasons:

When partial lot of order is to be handled from the rest due to quality reasons.
If capacity bottle necks exists.
Material is committed for part of order qty.

Features:

The split operations and the material assigned are copied into the child order.
The structure of the parent order does not changes while the split off operations are copied into the child order

Status for parent order : SPLT
Status for the child order: SPLE
For operation : SPLT

Restrictions:

The parent order and the child order must be settled to same cost collector
Read PP Master data is not possible
Confirmations at header level is not possible

Steps to perform split:

In OPL8 Set the indicator cost collector
Default Rule -Periodic settlement(PP2)
CK11N do standard cost estimate
KKF6N Create cost collector
Create production order with op10,20,30,40
Go to op overview
Select the op from which you want to split (exop20)
Go to functions ----> Split order
Enter the qty ,if necessary a different order type for the child order
Execute
Order will be splitted .
The order can be splitted even from op10 itself
Goto MD04
Two orders will be created
Go to op overview of each order and there you can see the splitting.

WBS Elements

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What is WBS element?
What is the Tcode to get to that screen?
What is the need and pupose of WBS element?
Do we happen to work on Functional module during our implementaion project?
In what scenario/situation we will be working on WBS?

WBS is nothing but Work Breakdown Structure. It is mainly used in Project System (PS) module. Tcode : CJ20N

For any project defined we must have atleast one WBS. Within this WBS we can have networks. Networks are nothing but the series of activities. Material are used to perform the activities.

To explain in detail just consider one example:

Govt of india wants to have Roads to be build through out the india. So Project can be defined in sap as "Connectivity".

WBS can be roads within different states like Roads for Gujarat, Karnataka etc.. i.e. WBS Gujarat, WBS Karnataka etc.

We can define different networks for these WBS like Road Between Ahmedabad to Surat or Between Bangalore to Belgham.

For this network we can have many activities like Land selection, Land Preparation, Road Building, Final finishing etc etc.

Hemal's example was a good example. Project Systems comes into play only when the industry's business is based on projects like... Construction companies, Engineer to Order scenarios. You may not see anyone using PS module for retail business. As Hemal explained in that example, you have a main project which is broken down into WBS elements. You can use the TC CJ20N to create the project and the WBS elements. Each WBS may have mutiple Networks associated and each Network may have multiple Network Activities as explained in the example by Hemal.

On the Sales Order, if your client is implementing PS module, you may have to attach the Sales Order to the WBS element it belongs to. WBS element is nothing but a bucket where all the activities belonging to that particular part of the project are captured. In the example, WBS Gujurat will tell you how many Sales Orders were created for the Gujurat sector, howmuch was spent on raw materials, what's the currect stock ([roject stock) available. How many Production Orders have been confirmed and howmany of them are getting confrmed in the future. How many invoices have been generated or how much revenue has been generated for that particular sector. How many deliveries have been made, what deliverables are still not accomplished.

So as you can see, PS is the center stage for all the modules that are being implemented like FI/CO, SD, MM, PP in this example. You can have cost centers and work centers defined. You can also have profit centers assigned at the plant level and get reports on varius selection criteria.

In a complete cycle of PS, like in reality, you initiate a project, you confirm/release the WBS/activities as per requirement, you execute the project and you close it.

One cannot initiate an activity unless it has been released by the project manager. Everything is accountable here and every dime is counted and at the end you know howmuch did you spend or make on each sector (WBS). Dont get confused with the term sector here... I am using it just for the explaination purposes. :)

In one typical example, the company I was working with until not too long ago, had Deliveries from the Project (TC: CNS0). We never used VL01N. We used CNS0 to create a delivery and then used VL02N for confirming the picking quantity for the already created delivery document.

I hope this should help you at least a bit. I'm not a PS consultant so I may not know a whole lot but trying going to CJ20N and you will see a lot yourself.

PS concultants are one of the highest paid consultants. Their supply is less and so is the demand. They are expected to understand real world business processes very well and they are generally the center stage of a project.

1) What is WBS element?
2) What is the Tcode to get to that screen?
3) What is the need and pupose of WBS element?
4) Do we happen to work on Functional module during our implementaion project?
5) In what scenario/situation we will be working on WBS?

WBS is nothing but Work Breakdown Structure. It is mainly used in Project System (PS) module. Tcode : CJ20N

For any project defined we must have atleast one WBS. Within this WBS we can have networks. Networks are nothing but the series of activities. Material are used to perform the activities.

To explain in detail just consider one example:

Govt of india wants to have Roads to be build through out the india. So Project can be defined in sap as "Connectivity".

WBS can be roads within different states like Roads for Gujarat, Karnataka etc.. i.e. WBS Gujarat, WBS Karnataka etc.

We can define different networks for these WBS like Road Between Ahmedabad to Surat or Between Bangalore to Belgham.

For this network we can have many activities like Land selection, Land Preparation, Road Building, Final finishing etc etc.

Hemal's example was a good example. Project Systems comes into play only when the industry's business is based on projects like... Construction companies, Engineer to Order scenarios. You may not see anyone using PS module for retail business. As Hemal explained in that example, you have a main project which is broken down into WBS elements. You can use the TC CJ20N to create the project and the WBS elements. Each WBS may have mutiple Networks associated and each Network may have multiple Network Activities as explained in the example by Hemal.

On the Sales Order, if your client is implementing PS module, you may have to attach the Sales Order to the WBS element it belongs to. WBS element is nothing but a bucket where all the activities belonging to that particular part of the project are captured. In the example, WBS Gujurat will tell you how many Sales Orders were created for the Gujurat sector, howmuch was spent on raw materials, what's the currect stock ([roject stock) available. How many Production Orders have been confirmed and howmany of them are getting confrmed in the future. How many invoices have been generated or how much revenue has been generated for that particular sector. How many deliveries have been made, what deliverables are still not accomplished.

So as you can see, PS is the center stage for all the modules that are being implemented like FI/CO, SD, MM, PP in this example. You can have cost centers and work centers defined. You can also have profit centers assigned at the plant level and get reports on varius selection criteria.

In a complete cycle of PS, like in reality, you initiate a project, you confirm/release the WBS/activities as per requirement, you execute the project and you close it.

One cannot initiate an activity unless it has been released by the project manager. Everything is accountable here and every dime is counted and at the end you know howmuch did you spend or make on each sector (WBS). Dont get confused with the term sector here... I am using it just for the explaination purposes. :)

In one typical example, the company I was working with until not too long ago, had Deliveries from the Project (TC: CNS0). We never used VL01N. We used CNS0 to create a delivery and then used VL02N for confirming the picking quantity for the already created delivery document.

Validation in PS

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I am trying to use validation in the Project. Can any one tell when are the call up points 110 and 120 trigerred ?

I want to validate one of the user defined fields in WBS.

Everything is working fine when I simulate the validation. But when I enter a value in the user defined field and save the project then I do not get the error message as expected.

Does anybody have an idea what could be wrong ??

Answer :

Please see if you have checked the check box for Automatic validation in the relevant project profile.

Modular BOM

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Modular Bill of Material (BOM) is a critical element in defining the product structure of an end-item.

Modular BOMs define the component materials, documents, parts and engineering drawings needed to complete a sub-assembly. While the term BOM and Modular BOM are most commonly used in association with physical products, the concept can be used in a variety of industries (software, medical records, etc.) Modular BOMs are used by modern information systems to serve a variety of purporses, they define the components needed to produce a subassembly, they provide cost information for each component and "rolled-up" cost for the overall subassembly,

For option-based, configurable products (think automobiles, PC's, etc.) companies needed to plan every combination and permutation of options to ensure they could fulfill customer demands. With a modular BOM structure, companies can plan the demand for each module independent of the end-item demand by estimating the popularity of the module sub-assembly.

Bill of materials

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Bill of materials (BOM) is the term used to describe the "parts list" of components needed to complete a saleable end-item.

BOMs are hierarchical in nature with the top level representing the sub-assembly or end-item. For example the end-item BOM for a Personal computer would list the computer, its major sub-assemblies (board, chassis, modem, keyboard, display, etc.) as well as additional materials needed for a complete saleable product -- shipping box, user manual, packaging, packaging labels, etc.

The BOMs that describe the sub-assemblies are referred to as Modular BOMs. An example of this is the NAAMS BOM that is used in the automative industry to list all the components in an assembly line. The structure of the NAAMS BOM is System, Line, Tool, Unit and Detail.

A bill of material can define products as they are designed (Engineering Bill of Material), as they are ordered (Sales BOM), as they are built (Manufacturing bill of material), or as they are maintained (Service BOM).

The different types of bills of materials dependent upon the business need and use for which they are intended.

A bill of material can be displayed in following formats:

the single-level bill of material,
indented bill of material,
modular (planning) bill of material

In process industries the bill of material is also known as the formula, recipe, or ingredients list

BOM

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A configurable Bill of Material (CBOM) is used by industries that have multiple options and highly configurable products (Telecom Systems, Data-center Hardware (SANS, Servers, etc.), PCs, Autos, etc.)

The CBOM is used to dynamically create "end-items" that a company sells. The benefit of using CBOM structure is it reduces the work-effort needed to maintain product structures. The configurable BOM is most frequently driven by "configurator" software, however it can be enabled manually (manual maintenance is infrequent because its unwieldy to manage the number of permutaions and combinations of possible configurations)

The development of the CBOM is dependent on having a Modular BOM structure in place (see Modular BOM). The Modular BOM structure provides the assemblies/sub-systems that can be selected to "configure" an end-item.

Production Planning ( PP ) Tutorial.pdf

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SAP PP Frequently Asked Question

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Q: Where can I find any SAP PP Books for reference?

A: There ONLY one SAP PP books available which can be found in Amazon is :
Administering SAP R/3: The Production and Planning Modules

Q: I have some other Production Planning and Control question, where can I asked it?

A: Well, consider joining a PP forum.

Q: How to configure the planning calendar for the ATP calculation where goods are shipped every other working day?

A: Use Transaction MD25 and define calculation rule for every other working day. Check the lot size settings in OMI4 and
maintain relevant data in MMR.

Q: We have two different production lines with different operations. One production line works 5 days a week and the
other 7 days a week. The factory calendar is assigned to the plant for 5 days a week. This calendar is checked when
MRP is run.
How can we assign 5 day a week and 7 days a week against a factory calendar to the related resources? Is it possible to
have two types of calendars?

A: Assign factory calendars to the work centers.

Q: What is the difference between by-product and co-product and how do you differentiate them in a BOM?

A: In case of Co-product costs are settled with a apportionment structure. In case of By-product the price of this by-product
is credited to the order or the material stock account of the lead material being manufactured. Co-Product as well as
by-product are defined as BOM Components/Items. Both of them have negative quantities. ( Not all negative quantity
items fall under these categories!). When BOM is created for FERT , you can see one indicator in COMPONENT
DETAILS screen for co-product. You need to define the co-products with this special indicator .

Q: What are some important tables used in PP ?

A: For orders:
CUAFVD dialog structure for order headers and items

AFPO - Order item
AFFLD Order: Dialog table for order sequences (AFFL)

MOPER Operation for production order
KBED Capacity requirements

AFRU Order completion confirmations
RESB Reservation/Dependent Requirements
AFFHD Structure of PRT's in orders
SOPER Sub-operations

SAFRU Sub-operation confirmations
SKBED Capacity requirements for sub-operation

MRP table is MDTB.
For PI:
CAUFV - AFVC Operation within an order

AFFT Order Process Instructions
AFFV Order process instruction values

Some other tables of interest:
PLKO, MAPL , PLAS.

Bills Of Material

Q: We have a BOM - 'A' with two packing materials 'X' and 'Y'. For 1000 units of 'A', 1 packing material of 'X' is required
and for 50 units of 'A', 1 packing material of 'Y' is required. Base quantity of 'A' is defined as 1000. How can I define
'X' & 'Y' or in fact 'A'?

A: Make the base quantity of 'A' as 5000. The resulting component quantities would be 5 of 'X' and 100 of 'Y'.

Work Centers

Q: Can we have more than 6 standard values in standard value key?

A: One way to achieve this is to create another operation step using the same work center. However this shall be with a
control key that is not a milestone. When the milestone operation is confirmed, the previous operations up to the next
milestone are automatically confirmed. To get the desired number of standard values , all the 'non milestone' steps can
be built depending on the need.

Routing

Q: Can we use same routing for materials undergoing the same process/operations? Can we avoid separate routing for each
and every material produced?

A1: Presume that there are 50 products and the fabrication shop uses a set of 10 machines. If all these products use the same
settings of the machines, Reference Operation Sets (task list type S) can be setup for common processes that use the
same work centers. However costing, scheduling and capacity will be affected if each product has different setup time and
Reference Operation sets can not be used.
A routing for each material number ( type N or R) has to be set up and within that routing, the Reference Operation Set
can be used.
However you can by try utilizing the KMAT material and product variants invariant configuration to avoid separate routing
for each material.

A2: You may create a routing group. Go into routing creation and enter the plant and the group name. If you want you may
name the group , else name is assigned by internal counter). Create the routing with the work centers, operation times, etc.
Go to the "Header overview" screen and click on the "Mat Alloc" screen. Fill in the blanks with all the material masters
that use this routing.

A: In routing, carry out scheduling. Go into the routing operation overview and follow Extras -> Scheduling -> Results. The
pop-up window displays the scheduling data. At the bottom there is a pushbutton to copy the scheduling data to the
material master Check this push button to update master data.

Q: We have deleted a group key in an operation in routing and the same does not appear for this routing (CA02). But we
noticed that entries are maintained in table PLPO and the deletion indicator is not set. How does the system remember this
deletion of group key?

A: You may look at the tables PLKO, MAPL and PLAS.

Sales & Operations Planning

Q: We defined SOP in months. However during SOP transfer to demand management, our independent requirements are
appearing in weeks. How can we correct this from weeks into months ?

A: Check transaction OMPA for general split. OMPS - based on the MRP group. Ensure that MRP group assigned to the
material. Delete any allocations in these tables. Then periods will be transferred to Demand Management with the same
splits as in SOP. Also check whether the value of period is set as "month" at your plant level in Transaction 'OMP7'

Demand Management

Q: Sales quantities in SOP for certain days are transferred into Demand Management and are shown as planned independent
requirements. We need to keep the settings in SOP and change the periods in Demand Management? We would like to
have a rolling horizon, for ex: the following 4 weeks on a daily basis, after that on a monthly basis. What is the best way to
do this?

A: Use the automatic period split function.

M R P

Q: We have a lot size procedure here which is creating more order proposals. How do you set the limit value for maximum
number of MRP order proposals per date in IMG?

A: Under customization, try materials management->consumption based planning->maintain all plants

Q: What is the difference between "planned consumption" and "Unplanned consumption"? Can safety stock calculation be
done on either of these?

A: While customizing movement types (OMJJ) it is defined as to which set of consumption values gets posted during the
material movement. For some it may always be the total consumption and for some it is always the unplanned one and for
some it is dependent on whether the issues were done with reference to a reservation ie., a planned consumption. The way
these consumption values are taken into account in MRP is defined in the customizing of MRP types.
For Reorder point planning (VM) the total consumption is used to calculate the safety stock and the reorder point.
For Forecast based planning (VV) the total consumption is used to build the forecast which will be used to compile the
order proposals.
For Deterministic MRP (PD) the unplanned consumption is used to calculate the forecast which in turn is added to the
actual demand.

Q: We want the system to run a single level MRP automatically on receipt of sales order. How to configure triggering event
based MRP?

A: This can only be run if material master has planning strategy 41 (made-to-order) in the MRP2 view. We need to run for
other MRP types. We have to create a user exit in the sales order processing (VA01) to start MRP based on data from
our sales transaction.

Q: We have an assembly 'A' using a subassembly 'B'. 'B' in turn uses raw material 'C'. Item 'A' is an MPS and is duly marked
in Material Master. Item 'B' and 'C' are marked as 'PD'. When demand for 'A' is entered and MPS is run , upto which level
the requirements are taken care of?

A: MRP can be run depending on your requirement. For example:
Single Item / Single Level from MPS - Transaction Code MD42 - Only the top MPS item ( 'A' in this case) is planned
and dependent requirements will be passed to MRP item ( 'B' ) . Run MRP, Transaction MD02 on 'B' to plan it and all
MRP items below .
Single Item / Multi Level from MPS - Transaction Code MD41 - All levels are planned - A , B & C
Total Planning from MPS online or background - Transaction Code MD40 or MDBS
Without marking the checkbox " Process MRP materials" is like case ( 1) above and with the checkbox marked is
like case (2 ).

Production Orders

Q: We get an error message "Control parameters for scheduling not defined" while creating test production Orders. Why?

A: Before you attempt creating Production orders, configure your
Order types- Transaction Code OPHJ
Order type Dependent parameters - Transaction Code OPL8
Backorder Scheduling - Transaction Code OMIH
Scheduling Levels - Transaction Code OMIF

Q: We are trying to create Purchase Requisition from MRP run. We have material , info Record, Source list , Demand in
place. MRP is always creating plan order. Why?

A: Check the procurement type in MRP view of material master. Check 'Create Purchase requisition' indicator while running
MRP. If you want purchase requisitions to be created in the opening period, select the for MRP control parameter
'create purchase requisitions' as '1'.

Q: What is the option "Documented goods movements" on Selection of Individual Object Lists (transaction code CO28)?

A: Use Transaction code OPL8 to customize by choosing the order type, select all the checkbox under "Documentation of
goods movements" at the bottom of the page. Create a new Production order, make GI to it, and run the report.

A: Do a data collection first.
Menu Path - Accounting->Controlling->Product cost acctg->Process mfg->Information system->
Cost object hierarchy->data collection
(If you are using order hierarchy you would select order hierarchy in place of cost object hierarchy in the menu path.)
Then,
Accounting->Controlling->Product Cost Accounting->Order Related Production->Information System
Choose Report Period Costing - Target/Actual production variance

Q: We have two components ( 'X' & 'Y' ) in a production order in a process oriented production process. When 50 numbers
of component 'X' are issued, we need the system to automatically issue 100 numbers of component 'Y' based on ratio
of 1 to 2. Where do I specify these ratios?

A: You can define the ratio in BOM and material may be issued with reference to BOM.

Q: We have two storage locations are '0001' and '0600'. Default storage location in Process order is always '0001' What
determines this default location?

A: Look into OSS notes: 100757, 63493, 96262, 87843, 82033, 64946.
The Storage location as configured in the Supply area has the highest priority.

A: With the following settings, the batches are selected the moment the production order is released.
1: Set up batch determination the way that the batches in batch selection are sorted the right way. e.g. sorted by expiry date
2: Use automatic batch selection in disp view.
3: Ensure that the components are allowed to be back-flushed (material master / work center)

Q: We want to report on several status combinations like each order that has status 'Not deleted' and 'Not technically
completed'. What set up is required?

A: Check transaction CO28. In the selection screen note the possible selection 'System Status' . You can select TECO for
technically complete an DLT for deleted from the list. Select the Excl. indicator also.
You may also try transaction CO26 (Logistics -> Production -> Production control -> Control -> Information systems ->
Order Info System -> Object overview). Before executing the transaction report, combinations of statuses can be selected
or exclude them.

Q: How can we shut off the "automatic costing indicator" and the "automatic scheduling indicator" which go on when the
production order is released?

A: For "no automatic costing" follow the IMG path
Production -> Production orders ->Master data -> Order - >Define order type dependent parameters
Select the order type for which u automatic costing is not required. In the controlling settings, select "no automatic costing"
For "no automatic scheduling" , follow the IMG path :
Production ->Operations - >Scheduling -> Define control parameters
Select the order type and go to details. Deselect " automatic dates "
Alternatively, you can find indicators in the control key, which is in the routing. Transaction OPL8 gives you costing
indicators (Order type dependent parameters), and OPJU (control table for scheduling) gives some scheduling options.

Variable Size

Q: How can I use variable size items?

A: For example, consider an item A with 'kg' as base Unit Of Measurement(UOM) and 'm3' as stock keeping/issue unit.
Conversion factor is 1kg = 2.4 m3.
In the BOM of 'B' ,number of A required are specified (say 5).
Specify the 3 variable dimensions i.e. length, width & thickness- say 2000mm X 3000mm X 4mm = 0.024 m3
As per BOM - 'B' , the quantity of A required is 0.024 X 5 = 0.120 m3
If a production Order is released for 15 numbers of 'B' , the quantity of variable size unit will be 1.20 m3.
You can change the length, width or thickness in the production order & check the resulting variable size item quantity. At
the same time this requirement can be seen in 'kg' in stock/requirement list.

Is there a transaction or Report available to see the scrapped quantity of a particular material where goods issue is done using movement type 551?

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If you want to manage the inventory of Scrap, create another material ID for scrap and receive as by-product. When you issue goods against Movement type 551, the material is removed from inventory by writing it off the books.

Is it possible to generate Purchase requisition (PR) with reference to Scheduling Agreement?

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PR can be created with reference to another PR and can not be created referencing a PO or Scheduling agreements. PO & Scheduling are created and controlled by purchasing organizations. PR can be created by even end users. For creating PR with reference to another PR, follow the menu path:
Purchasing->Requisition->Create.
Requisition->Copy reference and enter.
However requirement can be generated with reference to Scheduling agreement when MRP is run. For this to happen, source list has to be maintained for that item-vendor combination and the MRP shall be properly set.

How to configure the planning calendar for the ATP calculation where goods are shipped every other working day?

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Use Transaction MD25 and define calculation rule for every other working day. Check the lot size settings in OMI4 and maintain relevant data in MMR.

How can we track requisitions that have the deletion indicator set? Can we track the date in which the deletion indicator was set?

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You can refer the change document tables cdpos and cdhdr. You can also refer Transaction ME53 under menu path goto-statistics-changes, where the complete audit trails of changes, including deletion are stored.

How can we make a Taxcode as default on purchase order item detail screen

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A1: Use condition type NAVS with access sequence 0003 to default the taxcode in the purchase order item using conditions.
A2: Go to IMG.
Materials Management -> Purchasing -> Purchasing order processing ->define screen layout at document level.
Search for the transaction ME21.Double click on ME21. Then search for TaxCode. It is advisable to configure also the info record. The tax code should be a required entry, and whatever you specify here will be the default value in the Purchase order.
Materials Management -> Purchasing -> Purchasing info record -> define screen layout.
When you get here you search for the transaction ME12 ,double click here; search for Input VAT indicator.

How can we delete materials permanently from Material master?

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Use transaction MM70 - Material Master->Other->Reorganization->Material->Choose.
Build variant with selection range of material master records to be selected for deletion and maintain run parameters. Execute.
Use transaction MM71 - Material Master-> other-> Reorganization->Material->Reorganization
Build a second variant
Maintain run parameters and execute.
It is also important to remove the records manually from info record, POs, PRs, reservation etc for successful deletion of the material.

How can I use variable size items?

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For example, consider an item A with 'kg' as base Unit Of Measurement(UOM) and 'm3' as stock keeping/issue unit. Conversion factor is 1kg = 2.4 m3.
In the BOM of 'B' ,number of A required are specified (say 5).
Specify the 3 variable dimensions i.e. length, width & thickness- say 2000mm X 3000mm X 4mm = 0.024 m3
As per BOM - 'B' , the quantity of A required is 0.024 X 5 = 0.120 m3
If a production Order is released for 15 numbers of 'B' , the quantity of variable size unit will be 1.20 m3.
You can change the length, width or thickness in the production order & check the resulting variable size item quantity. At the same time this requirement can be seen in 'kg' in stock/requirement list.

How can I extend all material to a new plant?

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The SAP program - RMDATIND is used to create /update material master record.

Can we have more than 6 standard values in standard value key?

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One way to achieve this is to create another operation step using the same work center. However this shall be with a control key that is not a milestone. When the milestone operation is confirmed, the previous operations up to the next milestone are automatically confirmed. To get the desired number of standard values , all the 'non milestone' steps can be built depending on the need.

Possible Combinations of Configuration Profiles

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You often need to work with several configuration profiles within one configuration.

For example, the materials PC, MONITOR and KEYBOARD are configurable. The monitor and keyboard are also sold separately. You need to create separate configuration profiles for them, because this involves a multi-level configuration.

However, there are restrictions on the profiles you can select for subordinate components. You need to work with profiles that are allowed in combination with the scenario for the header material.

The following table shows the possible combinations:

Header Material Subordinate Materials	Plnd/Prod. No BOM explosion	Plnd/Prod. Single-/multi-level BOM explosion	Single-/multi-level sales order	Single- /multi-level order BOM - knowledge-based -	Single- /multi-level order BOM - result-oriented -
Plnd/Prod. Order No BOM explosion	C	C	A	C	C
Plnd/Prod. Order Single-/multi-level BOM explosion	C	A	C	C	C
Single-/multi-level sales order	C	C	A	C	C
Single-/multi-level order BOM - knowledge-based -	C	C	A	A	C
Single-/multi-level order BOM - result-oriented -	C	C	A	C	A

Abbreviations:

A = Possible/allowed

B = Not allowed

C = No effect:

The material is handled as though it had no configuration profile.

Profile selection shows no options.

Comment

The only difference between the scenarios "single-level" and "multi-level" is that the "single-level" setting only explodes the assembly of the header material (single-level explosion). You can only assign values to the components of the header material.

Note

You can run check report RCU_CHECK_SUB_PROF_NO_BOM_EXPL to check configuration profiles on subordinate levels that you have defined with No BOM explosion, and change them if required.

Changing/Displaying/Deleting Configuration Profiles

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Procedure

Change Configuration Profile

From the variant configuration menu, choose Configuration Profile

Change.

You see a dialog box for specifying the object whose configuration profile you want to change. Select an object and confirm your entry.

To switch to another object, choose Extras ® Change confble obj.

Enter the name of the object.

Choose Profile overview.

You see the overview of profiles created for the object.

You can create new profiles for the configurable object by choosing Edit ® New entries.

Choose Profile detail to see the detail screen. You can change the settings for the profile.

You cannot change the settings Process: Sales order (SET) and Order BOM for a material once the material has been configured with the profile. If only the header material has been changed, the settings can be changed, but not if subordinate items of the BOM have been changed.

Display Configuration Profile

From the variant configuration menu, choose Configuration profile ®

Display.

For the rest of the process, see Changing a Configuration Profile above. However, you cannot make changes in display mode.

Deleting a Configuration Profile

You can only delete an existing profile by using Configuration profile ® Change if the profile has not been used to configure the object. If a profile has been used to configure a material in a sales order, for example, you can no longer delete the profile. The profile can only be deactivated by changing the status.

You can only use engineering change management to delete configuration profiles if no configured objects exist, or if the dat e of the configuration of all configured objects is before the deletion date.

Renaming a Configuration Profile

You can change the name of a configuration profile on the profile overview by choosing Rename.

Interface Settings

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Use

If you want to group and order characteristics on the value assignment screen according to your own criteria (Values ® Interface design), you must assign a name to the interface design on the Interface tab of the configuration profile. This activates the function on the value assignment screen.

The interface design you define on the value assignment screen is saved for the configurable object. If another configurable object is assigned to the same class, you can enter the interface design for this object, too. The characteristics are then displayed as you defined in the interface design.

However, you can only use an interface design for objects that are assigned to the same class. If the class assignment is not identical (for example, in multiple classification), you cannot enter the interface design you defined.

You can choose Settings to define object-specific settings for functions in the configuration editor. These settings are defaults for configuration, and can be overwritten for your user in the configuration editor.

Prerequisites

The configurable object must be assigned to a class.

See also:

Defining an Interface Design

Defining Settings for the Language

Defining the Scope and Display Options for Characteristics

Defining Settings for Pricing

Defining Settings for the Default Values

Defining Settings for the Configurator

Settings for Variant Matching

Multi-Level BOM Explosion

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Purpose

The setting BOM explosion: multi-level means that multiple levels of the BOM of a configurable material are exploded in the sales order, if the configuration profiles of the configurable assemblies also support BOM explosion. You can configure assemblies across multiple levels.

Variant product MULTIMEDIA_WORKSTATION supports multi-level BOM explosion. The BOM contains configurable material PC. This material supports single-level BOM explosion. The BOM of the PC contains another configurable material MONITOR.

Features

All configurable items are configured in the sales order, not only sales-relevant items.

You can use filters in the configuration profile to restrict the scope of the BOM items (see Filters for BOM Explosion).

Sales-relevant items are copied to the sales order as order items.

The characteristic values assigned to each configured item are saved.

In MRP, components and operations selected depend on the characteristic values assigned according to the principles of low-level configuration (see

Low-Level Configuration

If you define selection conditions for the BOM items of a subordinate configurable assembly, and these selection conditions refer to the characteristics of the assembly, you must use the object variable $PARENT to refer to the characteristics.

The selection conditions for BOM components of the PC must refer to the characteristics of the monitor with object variable $PARENT – for example, $PARENT.MANUFACTURER = 'Sony'.

This type of order processing lets you use constraints to infer values for configurable materials on different levels.

Prerequisites

The configuration profile of the header material has the configuration parameter BOM explosion: multi-level.

The subordinate materials whose BOMs are to be exploded in the sales order must also have a BOM explosion parameter (single-level or, preferably, multi-level).

Process Flow

Create a sales order and enter the configurable material as an order item.

You see the configuration editor, where you assign values to the characteristics of the header material. You can then display the result of the BOM explosion by choosing Result.

If any of the selected BOM components are also configurable materials, you can assign values to the characteristics of these materials. Depending on the configuration parameters, the BOMs of these materials are exploded on the result screen.

The header material appears as a sales order item. If the BOM contains further sales-relevant items, these are included as sub-items. The characteristic values assigned to the header material and the subordinate configurable materials are saved.

In the planned order or production order, BOM components and operations for the configured materials are determined according to the characteristic values assigned.

Single-Level BOM Explosion

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Purpose

The BOM is exploded on one level on the result screen in the sales order. Other configurable material can be contained in the BOM and these can be configured. However, the BOMs of these materials are not exploded in the sales order.

You can combine this setting with Process: Sales order when dealing with configurable material of the BOM that you want to assemble in a set structure.

See also: Process: Sales Order

Example

The materials PC and MONITOR are configurable. The monitor has its own configuration profile and characteristics. The configurable PC has the setting BOM explosion: single level in its configuration profile. On the result screen in the sales order, you see the selected components.

Configurable material MONITOR can also be configured in the sales order. However, the BOM of the PC is not exploded, because a single-level explosion only is defined for the header material. The configuration parameters for the material MONITOR are not important in this instance.

Features

All configurable items are configured in the sales order, not only sales-relevant items. The BOMs of these materials are not exploded in the sales order.

You can use filters in the configuration profile to restrict the scope of the BOM items (see Filters for BOM Explosion).

Sales-relevant items are copied to the sales order as order items.

The characteristic values assigned to each configured item are saved.

In MRP the required components are determined based on the characteristic value assignments for the head material and the subordinate items as well as the task list operations based on low-level configuration. (See also

Low Level Configuration

The selection conditions for BOM components of the monitor must refer to the characteristics of the monitor with object variable $PARENT – for example, $PARENT.MANUFACTURER = 'Sony'.

This type of order processing lets you use constraints to infer values for configurable materials.

Prerequisites

The configuration profile of the header material has the configuration parameter BOM explosion: single level.

Process Flow

Create a sales order and enter the configurable material as an order item.

You see the configuration editor, where you assign values to the characteristics of the material. You can then display the result of the BOM explosion by choosing Result.

If any of the selected BOM components are also configurable materials, you can assign values to the characteristics of these materials. However, the BOMs of these materials are not exploded.

In the planned order or production order, BOM components and operations for the configured materials are determined according to the characteristic values assigned.

Controlling the BOM Explosion in PP

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The following factors determine how a BOM is exploded:

BOM usage
BOM application
Filter defined in the configuration profile

BOM Usage

When you create a BOM, you must enter a usage. This usage defines which application areas (for example, sales and distribution, engineering/design, or production) a BOM can be exploded in. For example, the standard R/3 System supports usage 1 for BOM explosion in production. A BOM with usage 3 is relevant to sales and distribution, too.

The usage determines which indicators are active in the Item status dataset of BOM maintenance functions. This is where you specify whether BOM items are relevant to Sales or Production, for example.

Features

The BOM explosion is influenced by the application entered in the configuration profile. The application determines which usages of a BOM can be exploded and in which order of priority.

You enter the application for exploding the BOM in the configuration profile. However, please note that you can also enter an application for a sales order item category. This entry overwrites the setting in the configuration profile. Check the settings for the item category in Customizing for Sales and Distribution, by choosing Sales ® Sales Documents ® Sales Document Items ® Define item categories.

If you select the Sales order process in the configuration profile, ensure that the application supports explosion of sales-relevant BOMs and that sales-relevant BOMs have the highest priority.

You define an application that explodes first usage 1 and then usage 3. When you explode the BOM, the system first checks whether a BOM with usage 1 exists. If a BOM with usage 1 does exist, the BOM is exploded. If no BOM with usage 1 exists, the system checks whether a BOM of usage 3 exists.

Handling in the Sales Order

If usage 1 is supported by the application, the BOM for the material is found but cannot be exploded, because usage 1 in the standard R/3 System is not relevant to sales and distribution.

If usage 1 is not supported by the application, the system does not recognize in the sales order that a BOM exists for the material.

Filters in the Configuration Profile

In the configuration profile, you can define filters so that only certain items are displayed (see Filters for BOM Explosion).

Process: Order BOM

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Purpose

You use this processing option if you want to make customer-specific changes to the BOM of a material that you configure in the sales order. In the sales order, you assign values to the characteristics of the header material, but the BOM is not exploded in the sales order.

The BOM components that match these values are not determined until you call a special processing function. Subordinate configurable materials can be configured in this function, and you can make order-specific changes to the BOM.

There are 2 types of order BOMs:

The result-oriented order BOM saves the configured BOM with the manual changes.
The knowledge-based order BOM saves the super BOM with all manual changes and dependencies, not the configured BOM. When you explode the BOM, the dependencies are processed dynamically and only the selected items are displayed.

If you change the characteristic values assigned to the material in transaction VA01, VA02, or CU51, this may affect the order BOM.

Prerequisites

The configuration profile of the configurable material has the Process: Order BOM indicator selected, with a single-level or multi-level BOM explosion.

Process Flow

Maintenance of Order BOM not Allowed in Sales Order

Create a sales order and enter the configurable material as an order item.

You see the configuration editor, where you assign values to the characteristics of the header material. As you enter characteristic values, dependencies for the characteristics and values are processed.

The BOM is not exploded in the sales order. You cannot assign values to subordinate configurable materials in the sales order.

The header material appears as a sales order item.

Once you have saved the sales order, you can process the BOM for the sales order by choosing Bill of material ® Order BOM ® Maintain multi-level from the bills of material menu. The values assigned to the material in the sales order are displayed and cannot be changed.

Maintenance of Order BOM Allowed in Sales Order

You can only use this function if you select Result-oriented BOM in the configuration profile first.

Create a sales order and enter the configurable material as an order item.
You see the configuration editor, where you assign values to the characteristics of the material. As you enter characteristic values, dependencies for the characteristics and values are processed.
Choose Engineering to process the order BOM.

You can assign values to subordinate configurable materials or change values already assigned.
Exit configuration and return to the sales order.

The order BOM is saved as a result-oriented order BOM when you save the sales order.

The header material is shown in the sales order as an order item.

Result

In material requirements planning (MRP), requirements are determined for the order item. To ensure that MRP checks whether a material has an order BOM, set the Sales order BOM indicator in Customizing by choosing Planning ® BOM Explosion/Determine Routing ® Define BOM explosion control.

See also:

For more information on maintaining order BOMs with and without Variant Configuration, together with the preceding and subsequent process, see the SAP Library under Logistics ® PP Production Planning ® PP Order BOM.

Process: Sales Order

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Purpose

You can use this processing type to describe variant products that comprise salable configurable materials. These products are supplied together, but are not assembled in a production order.

This processing form means that in the sales order you can only process sales-relevant BOM items.

You can use the item category group to define that requirements transfer and pricing are at component level.

For example, a PC is made up of the components monitor, CPU, keyboard, and printer. These components are all salable materials that are manufactured separately. In the sales order, you want to see the individual components that make up the computer as order items, as well as the whole computer. In the sales order, these products are grouped together in a SET. For this reason, this type of processing is also referred to as set processing.

The individual components of a BOM can be configurable products that are described by characteristics of their own. You must create a configuration profile for each of these materials, in order to assign the materials to a class. The superior configurable material only has a few characteristics that are relevant to all components.

In addition to the process, the BOM explosion settings for the header material must be specified in the configuration profile.

For a single-level SET structure, it is sufficient to define a single-level BOM explosion in the configuration profile of the PC.

BOM explosion: single-level setting and process Sales order.

If the BOMs of the assemblies (such as the printer) contain other configurable materials, you need the multilevel BOM explosion setting for the PC:

BOM explosion: multilevel setting and process Sales order.

If the header material supports multilevel BOM explosion, the configuration parameters of the assembly determine whether the BOM is exploded in the sales order.

If you only want the assemblies of the header material to appear in the sales order, and the components of subordinate assemblies are relevant to production, you can select the setting BOM explosion: Single-level and process Sales order for the configuration profile of the header material. The sales-relevant BOM of the header material is exploded in the sales order, and the production-relevant BOM is exploded in the planned order or production order.

Constraints

You can use constraints to infer values between configurable assemblies (for example, the printer and the CPU).

You can also use constraints to pass values from the PC to the assemblies, or from the assemblies to the PC.

Object Variable $PARENT

The selection conditions for BOM components of the printer must refer to the characteristics of the printer with object variable $PARENT – for example, $PARENT.Pages/min = '3'.

Prerequisites

Settings in the Configuration Profile

Before the components of a configurable material can appear as a set in the sales order, the parameters BOM explosion: Single-level or Multilevel and the process Sales order must be selected in the configuration profile of the material.

Settings in BOM Maintenance

Only BOM items that are defined as relevant to sales and distribution appear in the sales order – in other words, you can only configure components that are relevant to sales.

The BOM must be created with a usage that supports sales-relevant BOM items, and you must define the BOM items as sales relevant by choosing Item ® Status/long text (see Controlling the BOM Explosion).

Settings in the Material Master

Sales data must be maintained in the material master of the individual materials in the BOM.

If you want requirements transfer and pricing at component level, the configurable material must have item category group 0004.

Allowing Manual Changes

You can also change the BOM items of the header material to suit customer requirements. The change is copied to the sales order item. However, you can only change the BOM items if the Manual changes allowed indicator is set in the configuration profile of the header material. You can only change BOM items that are relevant to sales.

If manual changes are allowed, you can delete items from the BOM or insert items in the BOM. You can also make changes to existing items (for example, you can change the quantity).

Process Flow

Create a sales order and enter the configurable material as an order item.

You see the configuration editor, where you assign values to the characteristics of the header material. You can then display the result of the BOM explosion by choosing Result.

You see all BOM components that are selected according to the values assigned, and are relevant to sales.

You can also configure the configurable assemblies. You can use constraints to infer characteristic values between assemblies. Once you have configured all materials, you return to the order item entry screen.

All BOM items that were selected and are relevant to sales are displayed as subitems for the main item in the sales order.

For more detailed information on settings for item categories for transferring requirements and pricing, see Item Categories for Configurable Materials.

Note

If you select the process Sales order in the configuration profile, this may lead to problems in costing. You need to remember that each configured instance that has the Sales order setting, and each sales-relevant configured instance below the Sales order setting, represents a configuration of its own. This means that each configurable material with these settings has its own CBase. The use of object variable $ROOT in dependencies can easily lead to errors here.

Example

Item in the Sales Order	Material	Material Type	Settings in the Configuration Profile
10	Kmat1	KMAT	Sales order
20	Kmat2	KMAT	Sales order
: : 80	Fert1	FERT	-® No setting in profile, material is not configurable

Items 10 and 20 both represent separate configurations. The structure information is in sales and distribution only.

For this reason, object variable $ROOT must not be used if you use dependencies for item 80 (Fert1), because in this example item 20 (Kmat2) is the parent or root of item 80 (Fert1).

Process Overview

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Purpose

There are different processes for configurable materials in sales documents. You can specify these processes on the Confign initial screen tab in the configuration profile, by choosing the Confign parameters tab. The processes are described in the following scenarios:

Plnd/Prod. Order:

For information on this scenario, see:

No BOM Explosion

Single-Level BOM Explosion

Multi-Level BOM Explosion

You can use this processing type to describe variant products whose configurable materials are assembled using planned and production orders. The bill of material (BOM) can have single-level, multi-level, or no explosion.

Sales Order (SET)

You can use this processing type to describe variant products that comprise salable configurable materials. These products are supplied together, but are not assembled in a production order. Only sales-relevant BOM items are exploded in the sales order.

For information on this scenario, see Process: Sales Order.

Order BOM

You use this processing type if you want to make customer-specific changes to the BOM of a material that you configure in the sales order. In the sales order, you assign values to the characteristics of the header material, but the BOM is not exploded in the sales order.

For information on this scenario, see Process: Order BOM.

Availability of Components

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Use

If you select Component availability in the configuration profile, by choosing the Confign initial screen tab, then the Configuration parameter tab, you see the Availability pushbutton on the value assignment screen in the configuration editor. You can use this pushbutton to check the availability of the components that are selected according to the values you assign. The entire BOM is checked and exploded.

For this reason, in a SET structure we advise you to check availability of the individual materials (Process setting Sales order), not for the header material.

The availability check is just a snapshot, telling you whether the materials required are in stock at this moment. Several users can access the same material at once. This means that supply problems can sometimes be overlooked.

Only 2 pieces of a material are in stock, but the material is used in 3 BOMs. The availability check does not detect a supply problem. The availability check for all 3 BOMs shows 2 pieces in stock.

Features

On the value assignment screen, you can define additional settings for the availability check:

You can specify that a list of all components is shown with details of their availability.
You can specify that only missing parts are shown in the list.

Filters for BOM Explosion

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Use

By defining a filter in the configuration profile, you can determine the scope of the BOM items to improve system performance when you explode the BOM. The filter is active in high-level configuration, in result-oriented BOMs, and in SET processing.

Restrictions

You cannot define filters if you select the BOM explosion setting None.

Features

You can define the following filters:

Object type

Class, material, document, text

In the standard system, all object types are selected and therefore exploded in the configuration. Deselect the object types that you do not want to be displayed.

Item category, for example, stock or non-stock item

All item categories in the configuration are exploded in the standard system. Remove the selection for the item categories you do not want to be displayed.

Item status

You maintain the status of a BOM item in maintain BOM dependent on its usage.

All items are displayed regardless of their item status in the standard system. However, only the items with this status are displayed when you select specific item statuses. Items are not displayed that do not have the selected status.

Sort string

You can assign sort strings for BOM items in maintain BOM. You can restrict the display of the BOM items by using these sort strings.

Only items that carry sort strings are checked and only those that match are displayed. Items that have no sort string are always displayed.

See also:

Controlling the BOM Explosion

Class Assignment

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Use

Before you can configure an object, you need to assign the object to a class whose class type supports variant configuration. For materials and other configurable objects, this is class type 300 in the standard system, except for model service specifications, which have class type 301. When you assign the object to the class, you can use the characteristics of the class to describe the object.

Prerequisites

In Customizing for the Classification System, the Variant class type indicator must be set for the class type.

Features

Class Assignment Pushbutton

The assignment to a class is not the same as any classification. The class is just a container for the characteristics that are required for configuring the object.

If you set values, this has the effect of restricting the allowed values for configuration, rather than assigning values as in classification. You can assign several values to single-value characteristics.

The values you set are not default values. During configuration, you only see the values you set in the class assignment.

Class C_CAR has characteristics EXTRAS and COLOR. You assign configurable material CAR to class C_CAR. You restrict characteristic EXTRAS to values ‘Sports’ and ‘Luxury’, and characteristic COLOR to values ‘Red’ and ‘Black’.

When you configure the car, you only see the two values you set for both COLOR and EXTRAS, because you have restricted the allowed values in the class assignment.

To allow all values in configuration, do not set values in the class assignment.

Multiple classification

If the class type allows multiple classification, you can classify the configurable object in several variant classes. When you configure the object, you see the characteristics of all classes of a class type to which the object is assigned.

If you only assign a configurable object to an additional class later on, and configurations (such as sales orders) already exist, you can no longer delete the assignment to the additional class once you have saved it.

The sequence of classes has no influence on the sequence of characteristics on the value assignment screen.

See also:

SAP Library ® CA Cross-Application Components ® CA Classification

Creating a Configuration Profile

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Procedure

From the Variant Configuration menu, choose Configuration profile ® Create.

You see a dialog box. Select the object for which you want to create a configuration profile.

Enter the name of the object.

Confirm your entries.

3. You see the profile overview.

Enter a profile name and the class type whose classes you want to use for configuration. In Customizing for the Classification System, the class type must be defined as a variant class type.

Choose Goto

® Class assignments

or the Class assignments pushbutton to assign the object to a class. (You can also specify the class assignment in Materials Management by choosing Create/Change Material, or in the Classification System by choosing Assign Object to Class.)

You see the classification screen, where you enter the class.

Define allowed values for the configurable object if required.

You can only release a profile if you have assigned the configurable object to a class. (see also Class Assignment)

To go to the detail screen, where you define further settings, choose the Profile detail pushbutton or double-click on the profile.

Optional Settings on the Profile Overview

Organizational Areas

You can specify organizational areas for configuration. If you restrict a profile to specific organizational areas, you only see the characteristics that are relevant to your area when you configure the object.

You can change how characteristics are displayed according to organizational area for your user on the value assignment screen (see Organizational Areas).

Priority of Configuration Profiles

You can create several configuration profiles for a configurable material. The profile with the lowest number has the highest priority.

If you define several profiles for an object, you see a dialog box for selecting a profile when you start configuration. The profile with the highest priority is at the top of the list.

The priority is also relevant if you use Application Link Enabling (ALE) or intermediate documents (IDocs) to run configuration, rather than dialog mode. In this case, the profile with the highest priority is selected for the object.

Profiles that have no priority are at the top of the list, because they automatically have priority 0.

Profile Detail

Configuration Profiles for Materials

The configuration profile has several screens. Depending on what you enter for the BOM explosion and configuration process, fields are shown or hidden.

The parameters you maintain for a material apply to the material as a header material in a BOM structure. You cannot define separate settings for use of a configurable material as an assembly in a BOM.

By choosing the Assignments pushbutton, you can assign dependencies to the configuration profile. You also see this pushbutton on the basic data tab, once at least one dependency is assigned.

Basic Data Tab

In the basic data, you see the profile overview data.
You can determine whether the configuration process starts with a Start logo. To do this, you assign the document you want to display, such as a graphic showing the product you want to configure, to the variant class.

Configuration Initial Screen Tab
Configuration parameters

You specify the parameters for BOM explosion and the configuration process in the sales order.

You must enter a BOM application, unless you select BOM explosion: None:
You can enter a level of detail for a multi-level configuration. You can display configurable assemblies only in the BOM explosion. This improves system performance.
You can define a filter.
You can set the indicator for an availability check on assemblies.

Userinterf

Under Userinterf, you maintain the settings for the configuration editor user interface.

You can specify an interface design to group characteristics together on the value assignment screen.
You can choose Settings to define object-specific settings for functions in the configuration editor. These settings are defaults for configuration, and can be overwritten for your user in the configuration editor.
For all configuration parameters except BOM explosion: None, you can select screens for the configuration editor and define which screen configuration starts with. The start screen must be one of the allowed screens.

You can select the indicator for the configuration browser independently of the other start screens, because the browser is an additional screen section.

Configuration Profiles for Objects Other than Materials

You see the basic data, where you see the profile overview data.

You can define object-specific settings for displaying characteristics and characteristic values in the configuration editor. These settings are defaults for configuration, and can be overwritten for your user in the configuration editor.

See also:

On configuration parameters:

Controlling the BOM Explosion

No BOM Explosion

Single-Level BOM Explosion

Multi-Level BOM Explosion

Process: Sales Order

Process: Order BOM

Filters for BOM Explosion

Availability of Components

On settings:

Defining Settings for the Language

Defining the Scope and Display Options for Characteristics

Defining Settings for the Default Values

Defining Settings for Pricing

Defining Settings for the Configurator

Settings for Variant Matching

The Configuration Profile

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Purpose

You maintain configuration profiles for configurable objects to define central settings for configuring the object.

You can create several configuration profiles with different settings for an object. If an object has several configuration profiles, you must select a profile during configuration. You can only make changes to a configuration with the profile that you first used to configure the object.

Integration

You maintain configuration profiles for all configurable objects:

Configurable materials
Configurable standard networks
Configurable general maintenance task lists
Configurable model service specifications

Features

You define different settings in configuration profiles for materials than for other configurable objects.

You use the configuration profile to assign the configurable object to one or more variant classes. This links the object to the characteristics of the class for configuration.

Note that the class is then assigned to the configurable object, not the profile. The profile only allows you to go to classification.

You can define settings that affect the display options and scope of characteristics on the value assignment screen. You define these settings for each object, and they apply to the object wherever it is used. However, you can overwrite these settings for your user in the configuration editor.

You can use an interface design to group characteristics together and define a sequence on the value assignment screen. You need to assign a name to an interface design to enable further maintenance in the configuration simulation.

You can use the configuration profile to assign dependencies to a configurable object. You can only assign dependency nets to a configuration profile. If you assign actions and procedures to the configuration profile, you can manage them more easily because they are all in one place.

For materials, you must also maintain configuration parameters for BOM explosion. Depending on the configuration parameters you set, other fields in the configuration profile are hidden or shown.

You determine the status of the configurable object.

You can also define settings for the status in Customizing. In Customizing, choose Configuration Profile ® Configurable Objects ® Material ® Maintain Status.

Defining Classes as BOM Items

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Purpose

You can use class items to control the selection of variant parts in a BOM. Variant parts are classified in a class, and the class is entered in the BOM as a class item. When you configure the material, the class is replaced by a suitable variant part.

Class items can help you to simplify maintenance of BOMs for configurable materials:

You only enter one item for the class, instead of several items for the individual variant parts.
You do not need to create and assign selection conditions.
You can classify additional objects in the class at any time, without having to change the BOM.

When you configure the material, the class item is replaced by a specific component.

Prerequisites

You can only uses classes for classifying the following objects as BOM items:

Materials
Documents

The class type determines whether a class can be used as a class item in BOMs. In Customizing for the Classification System, the Class node indicator must be set for the class type. In the standard system, class types 200 and 300 are defined for materials, and class type 201 is defined for documents.

Configurable materials can be assigned to classes of class type 300. If a class item is replaced by a configurable material, this material is added to the configuration structure automatically.

Process Flow

Create characteristics that describe the objects.

Create your class using a class type for class items.

Maintain the additional data for the class (see the SAP Library CA - Cross-Application Components ® Classification (CA-CL) ® Classification (CA-CL) ®Additional Data).

Assign objects to the class and assign values to the characteristics of the class for each object.

Enter the class as a class item in the BOM of the configurable material – see the SAP Library Bills of Material (PP-BD-BOM).

Detail Screens For A Class Item

Entering Class Items

See also:

Selection from a Class Item

Variant Classes

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In variant configuration, a class is used to hold the characteristics that describe a configurable material. By linking the class to the configurable material, you allow the material to be configured using the characteristics of the class.

You can only use a class in variant configuration if the class has a class type that supports variant configuration. In the standard R/3 System, the class type for variants is class type 300. However, in Customizing for Classification, you can define other class types for variant configuration. In the step Define class types, you can set the Variant class type indicator for a class type.

Once you have created a variant class, you can do the following, as for any other class:

Classify materials in the class
These materials do not have to be configurable materials.

Set up a class hierarchy
This allows you to use inherited characteristics and restrict characteristic values.

Use the class to find objects

Class type 300 has 2 other special attributes, in addition to the Variant class indicator:

In classes of this class type, you can classify objects of different object types. This means that all the objects linked to the configurable material are classified in one class.

For example, if you create a sales order for a configurable material, this order is automatically classified in the variant class.

You can also use classes of class type 300 as BOM items. For more information, refer to

Classes as BOM Items

You define these two settings in Customizing for Classification, step Define class types.

Reporting: Characteristics and Values

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You can display all the characteristics that describe a configurable material. You also see information on whether an entry is required for a characteristic, whether a default value is defined for a characteristic, and whether dependencies are allocated to a characteristic.

Choose Environment

Reporting

Chars and Values

from the variant configuration menu.

You see the initial screen. Enter the material for which you want to execute this function. You can enter the following data:

– The date on which you want to execute the reporting function.

If the material has been processed with engineering change management on different dates, different characteristics may be assigned to the material on different dates.

– The language in which you want the characteristics displayed.

In characteristics maintenance functions, you can enter language-dependent descriptions for characteristics and for values with CHAR format.

– You can define that characteristics are displayed with values.

– You can define that the status of dependencies is checked. If a dependency that is not released is allocated to a characteristic or characteristic value, the indicator for dependencies is selected in the result of the report.

Once you have defined your settings, choose Execute.

You see the configurable material and the class to which the material is allocated. Below it, you see a list of the characteristics of the material. You can print this list.

If object dependencies are allocated to a characteristic or characteristic value, the O indicator is selected. If you are interested in the status, released and locked dependencies are displayed differently.

If a characteristic is required entry, the R indicator is selected.

If a value is defined as a default value, the D indicator is selected.

You can select a characteristic and display detailed information on its format and attributes.

Maintaining Characteristics for Configuration

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Use

When you create a sales order for a configurable material, this sales order must describe precisely how the product being ordered is to look. This description comes from characteristics and characteristic values.

A car, for example, has a large number of options that need to be described.

The graphic shows the individual product options such as engine, gears, paintwork, mapped as characteristics. You define values for characteristics, to allow you to select specific options, such as 'black' for paintwork.

To create characteristics, you use the standard functions in the classification system menu (see the SAP Library CA Cross-Application Components ® Classification (CA-CL) ® Characteristics (CA-CL-CHR ® Creating, Changing, and Displaying Characteristics).

Features

You can assign object dependencies to characteristics and characteristic values, to ensure that the values assigned are complete and consistent (see Characteristics (CA-CL-CHR): Creating Dependencies for a Characteristic and Maintaining Dependencies for a Characteristic Value).

You can define characteristics as restrictable, specifically for variant configuration. The values of a restrictable characteristic can be restricted during configuration to certain allowed values (see Restrictable Characteristics).

Routings for Configurable Materials

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Use

A routing (or task list) for a configurable material contains all the operations, operation sequences, and production resources/tools (PRTs) that are required to manufacture all variants of a configurable material.

Routings (task lists) for configurable materials are known as super task lists.

When you configure the material, you assign characteristic values that are used in production to determine the operations required.

In the processing industries, master recipes are used instead of task lists. Master recipes contain all the recipe objects that are required for all product variants.

Features

To maintain task lists for configurable materials, choose Routings ® Routing ® Create. You create the routing in the same way as for other materials.

You can assign dependencies to the operations, operation sequences, and PRTs in routings for configurable materials.

You can assign dependencies to the phases, operations, BOM items, and secondary resources in master recipes.

You can assign the following dependency types:

Selection conditions

To ensure that operations, operation sequences, and PRTs are selected when they are needed in a variant, you assign selection conditions to them.

Selection conditions also ensure that the correct objects in master recipes are selected.

See Selection Conditions and

Selection Conditions for a BOM Item and Operation.

Procedures (actions)

To change fields in operations and PRTs, such as the standard values, you use procedures or actions.

In master recipes, you can change fields in operations, phases, secondary resources, and BOM components.

See Reference Characteristics in Dependencies and Master Data References in Task Lists

See also:

PP Routings

Creating a Routing

Creating Local Object Dependencies for an Operation

Creating Global Object Dependencies in an Operation

PP–PI Master Recipes

Creating Master Recipes

Editing Configurable Master Recipes

Editing Global Object Dependencies

Editing Local Object Dependencies

Finding Objects in a Class Item

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Procedure

You can start the function for finding objects in a class item from the result screen, or in a multi-level, interactive configuration, you can select the class item from the Confign structure:

Select the class item and choose Find objects.

You see the characteristics of the class. You can enter characteristic values as search criteria.

Choose Find object again.

You see a list of objects that match your search criteria.

Select the object you want to copy and choose Copy objects.

However, this is only possible in the simulation, or in configuration processes Order BOM and Sales order (with the setting Manual changes allowed).

Result

On the result screen, the class item is replaced by the object you selected.

Selection from a Class Item: Example

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Create characteristic REARLIGHT_TYPE, with values Dtoplight Plus, Toplight, and FER.

Create class REARLIGHT with class type 200.

Define the following additional data for the class:

· The class can be used in bills of material (BOMs).

· The base unit of measure is piece.

· The item category for the resulting material is L (stock item).

You have created 3 materials – R1220, R1221, and R1222.

You classify there 3 materials in class REARLIGHT as shown in the following table:

Material	Value
R1220	Dtoplight Plus
R1221	Toplight
R1222	FER

You enter the class as a BOM item in the BOM for configurable material BIKE.

When you enter the BOM item, enter item category K first. You see a dialog box in which you must enter the class name and class type.

The class name for the item is not shown on the material item overview.

Assign characteristic REARLIGHT_TYPE to the variant class of configurable material BIKE.

The characteristic is now assigned to both the class item and the configurable material.

When you configure the BIKE, you can assign a value to characteristic REARLIGHT_TYPE.

Depending on the value you assign to the characteristic, the relevant material is selected from the class item.

For example, if you assign value ‘Toplight’ to characteristic REARLIGHT_TYPE, the class item is automatically replaced by material R1221.

Selection from a Class Item

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Use

You have various options for selecting a specific material or document from a class item (sometimes called "specializing" a class item).

The class item is automatically replaced according to the characteristic values assigned when the material is configured.

This means that object dependencies for the class item must make values for the characteristics of the class known.

If the system finds no values for the characteristics in the class item, first it looks for the values in the superior assembly, then if it finds none there, it checks the header material.

In a multilevel, interactive configuration, the class item can be replaced manually by searching for an object.

However, this is only possible in the simulation, or in configuration processes Order BOM and Sales order (with the setting Manual changes allowed).

Components that are automatically selected from a class item cannot be changed manually in order BOM processing or set processing.

Required Component

If you define in the class or the BOM item data that a component must be selected (Required component), the class item is marked as inconsistent until it is replaced by a material or document.

See also:

Defining Classes as BOM Items

Classification as a Selection Condition

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Use

You can classify the materials or documents that you enter as components in a BOM in the Classification System. The bolts that are selected for different variants can be classified in class BOLTS and entered as BOM items. You can use the classification data in variant configuration as a selection condition.

In BOM maintenance, you just define in the BOM item that the item’s classification controls whether it is selected – there is no need to enter a selection condition You can use the classification in any class type.

Prerequisites

The characteristics of the class in which the material or document is classified must all be assigned to the configurable material. The value assigned in configuration must be identical to the classification value before the material or document is selected.

Class BOLTS in class type 001 has characteristics LENGTH and HEAD_SHAPE. To use the classification of bolts as a selection condition, you must assign both characteristics to the variant class. Before a bolt can be selected, both characteristics must have both classification values assigned in configuration.

Activities

On the detail screen of the BOM item in BOM maintenance, enter the class type of the class in which the material is classified, and select Selection condition.

Selecting BOM Items

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Use

There are three ways of selecting variant parts in the BOM of a configurable material:

You enter the variant part as a BOM item and assign selection conditions to it

You classify the variant part in a class and enter the class as a class item in the BOM.

You use the classification data of a material or document as a selection condition.

A bike has different rear lights:

§ Dtoplight Plus

§ Toplight

§ FER

You have the following options for controlling which rear light is selected:

a You can create BOM items for the individual rear lights, and use selection conditions to define when each item is selected.

b You can create a class of class type 200 or 300 and classify the three rear lights in the class. You enter the class as a BOM item in the BOM.

When you configure the material, the class is replaced by one rear light.

c The rear lights were classified in the classification system (in a class of class type 001, for example). Characteristic REAR_LIGHT_TYPE has been defined for the rear lights. You assign this characteristic to the variant class.

You enter three items in the BOM for the rear lights. For each item, you define that its classification is used as a selection condition. If you set a value for characteristic REAR_LIGHT_TYPE when you configure the bike, the system looks for a rear light that has this value, and selects a rear light on this basis.

Super BOM

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Use

The bill of material (BOM) of a configurable material contains all the components that are required to manufacture the material. The BOM contains components that are only used in specific variants (variant parts), as well as components that are used in all variants (non-variable parts).

This is why BOMs for configurable materials are known as super BOMs.

Features

When you maintain BOMs for configurable materials, there are additional functions:

You can assign object dependencies to the BOM items for a configurable material.

You can assign the following dependency types to BOM items:

Selection conditions

To ensure that variant parts are selected when they are needed in a variant, you assign selection conditions to the variant parts.

See Selection Conditions and Selection Conditions for a BOM Item and Operation

Procedures (actions)

You can use procedures and actions to change field values in a BOM item, such as the component quantity.

See Reference Characteristics in Dependencies and Master Data References in Bills of Material

You can use classes as BOM items for configurable materials, as well as the other types of component. When you configure the material, the characteristic values you assign can trigger the replacement of the class by a material or a document that is classified in the class. You can use a class item instead of using several BOM items with selection conditions.

You can use the classification data of a material or document as a selection condition.

The BOM can contain components that are configurable materials. These configurable materials have item category N (non-stock material).

Material Master Data for Configurable Materials

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You use central maintenance functions to create material master records for configurable materials. There is some data that you need to maintain specifically for configurable materials:

Basic Data

Material is configurable indicator

Sales

Item category group

0002 or 0004

See Item Categories for Configurable Materials

Delivering plant

MRP

Strategy group	For example, 25
	See SAP Library PP Demand Management Strategies for Configurable Materials
MRP type	For example, PD Not ND
	See SAP Library PP Demand Management MRP Procedures
MRP lot size	EX
	See SAP Library PP Material Requirements Planning Calculating Procurement Quantity
Availability check (checking group)	02
	See SAP Library PP Demand Management Scope of the Availability Check
Individ./collective	1

Defining a Material as Configurable

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Use

If a material is configurable, you can:

Select one or more alternatives, even though they are represented by only one configurable material

Configure the BOM and routing of the material Maintain dependencies for BOM items and operations, so that they are only selected for certain variants

Maintain a

Configuration Profile

with a class assignment for the material, where you define central settings for the configurable object

Prerequisites

Before you can configure a material, the material master record must have the Material is configurable indicator selected in its Basic data.

You can create a material using a material type that has the configurable indicator defined in Customizing. This means that all materials created with this material type are configurable. In the standard system, material type KMAT is defined for this purpose.
You can define individual materials of other material types as configurable. To do this, set the Material is configurable indicator in the Basic data of the material master record.

If you want to configure a material, you must create it with a material type that has the Classification view defined as allowed in Customizing. Otherwise, the assignment of a material to a class cannot be processed correctly.

For information on how to create a material master record for a configurable material, see the SAP Library LO Managing Material Master Data.

Variant Configuration (LO-VC)

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Purpose

Variant configuration is for manufacturing complex products. The manufacturer is always having to offer new variants of its products. Often, new variants are created by modifying existing product designs as you process the order. The important thing is to react quickly to customers' requirements.

The customer determines the features of the product. A customer buying a car, for example, can choose the features of the car and combine these features as required.

The product configurator improves information exchange between sales, engineering, and production. Variant configuration helps the customer or salesperson to put together specifications for the product and ensure that the product can be produced from these specifications. It also ensures that production costs do not overstep the mark.

Integration

Variant configuration is integrated in the following applications:

CA Classification
LO Material Master
PP Bill of Material
PP Routings
PP–PI Master Recipes
SD Sales
SD Conditions
MM Purchasing
CO Costing
PP Material Requirements Planning (MRP)
PP Production Orders

You can configure the following objects:

Materials
Standard networks in the Project System.
PM General maintenance task lists
Model service specifications

Features

You do not need to create a separate material for each variant of a product in your company. You can use one configurable material to cover all variants. You create a super BOM and a super routing for this material, containing all the components and operations for producing all variants of the product.

To define the features of a configurable material, you use characteristics. To enable you to use characteristics to configure a material, you assign the material to a class of class type 300. Possible characteristics of a car, for example, are model, country, color, and engine. The customer can choose from among different options for each characteristic (values).

The only limitations are combinations of features that are not possible for either technical or marketing reasons. You cannot combine all types of car engine with all types of transmission, for example, or certain types of upholstery are only available for more expensive models. In Variant Configuration, you use dependencies to control this. This prevents combinations of options that are not allowed. Dependencies also select exactly the right BOM components and operations to produce a variant.

Each configurable object must have a configuration profile. The configuration profile for a material controls the configuration process in the sales order.

You can make the price of a variant dependent on the characteristic values assigned (Pricing). You can use variant conditions to define surcharges and discounts for a variant.

For variants that are required frequently, you can create material variants, which can be produced without a sales order and kept in stock. When you receive a sales order, you can check whether the variant required is in stock, so that you can deliver immediately.

variable size

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Q: How can I use variable size items?

A: For example, consider an item A with 'kg' as base Unit Of Measurement(UOM) and 'm3' as stock keeping/issue unit. Conversion factor is 1kg = 2.4 m3.
In the BOM of 'B' ,number of A required are specified (say 5).
Specify the 3 variable dimensions i.e. length, width & thickness- say 2000mm X 3000mm X 4mm = 0.024 m3
As per BOM - 'B' , the quantity of A required is 0.024 X 5 = 0.120 m3
If a production Order is released for 15 numbers of 'B' , the quantity of variable size unit will be 1.20 m3.
You can change the length, width or thickness in the production order & check the resulting variable size item quantity. At the same time this requirement can be seen in 'kg' in stock/requirement list.

Production Orders

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Q: How can we shut off the "automatic costing indicator" and the "automatic scheduling indicator" which go on when the production order is released?
A: For "no automatic costing" follow the IMG path
Production -> Production orders ->Master data -> Order - >Define order type dependent parameters
Select the order type for which u automatic costing is not required. In the controlling settings, select "no automatic costing"
For "no automatic scheduling" , follow the IMG path :
Production ->Operations - >Scheduling -> Define control parameters
Select the order type and go to details. Deselect " automatic dates "
Alternatively, you can find indicators in the control key, which is in the routing. Transaction OPL8 gives you costing indicators (Order type dependent parameters), and OPJU (control table for scheduling) gives some scheduling options.

Production Orders

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Q: We want to report on several status combinations like each order that has status 'Not deleted' and 'Not technically completed'. What set up is required?
A: Check transaction CO28. In the selection screen note the possible selection 'System Status' . You can select TECO for technically complete an DLT for deleted from the list. Select the Excl. indicator also.
You may also try transaction CO26 (Logistics -> Production -> Production control -> Control -> Information systems -> Order Info System -> Object overview). Before executing the transaction report, combinations of statuses can be selected or exclude them.

Production Orders

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Q: We need to do GI of components to production order using Back-flush. The component stock is managed in Batches. The Batch to be back-flushed is selected by FIFO from the issue storage location. How can we set this up?
A: With the following settings, the batches are selected the moment the production order is released.
1: Set up batch determination the way that the batches in batch selection are sorted the right way. e.g. sorted by expiry date
2: Use automatic batch selection in disp view.
3: Ensure that the components are allowed to be back-flushed (material master / work center)

Production Orders

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Q: We have two storage locations are '0001' and '0600'. Default storage location in Process order is always '0001' What determines this default location?
A: Look into OSS notes: 100757, 63493, 96262, 87843, 82033, 64946.
The Storage location as configured in the Supply area has the highest priority.

Production Orders

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Q: We have two components ( 'X' & 'Y' ) in a production order in a process oriented production process. When 50 numbers of component 'X' are issued, we need the system to automatically issue 100 numbers of component 'Y' based on ratio of 1 to 2. Where do I specify these ratios?
A: You can define the ratio in BOM and material may be issued with reference to BOM.

Production Orders

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Q: We would like to have a report/inquiry that would indicate variances (materials, material quantities) between material recipe and actual process orders. We tried ME2M but this gives us a list of purchasing documents and not the consumption deviation. Where can I get such consumption deviation (master recipe Vs. Process> Orders)?
A: Do a data collection first.
Menu Path - Accounting->Controlling->Product cost acctg->Process mfg->Information system->Cost object hierarchy->data collection
(If you are using order hierarchy you would select order hierarchy in place of cost object hierarchy in the menu path.)
Then,
Accounting->Controlling->Product Cost Accounting->Order Related Production->Information System
Choose Report Period Costing - Target/Actual production variance

Production Orders

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Q: what is the option "Documented goods movements" on Selection of Individual Object Lists (transaction code CO28)?
A: Use Transaction code OPL8 to customize by choosing the order type, select all the checkbox under "Documentation of goods movements" at the bottom of the page. Create a new Production order, make GI to it, and run the report.

Production Orders

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Q: We are trying to create Purchase Requisition from MRP run. We have material , info Record, Source list , Demand in place. MRP is always creating plan order. Why?
A: Check the procurement type in MRP view of material master. Check 'Create Purchase requisition' indicator while running MRP. If you want purchase requisitions to be created in the opening period, select the for MRP control parameter 'create purchase requisitions' as '1'.

Production Orders

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Q: We get an error message "Control parameters for scheduling not defined" while creating test production Orders. Why?
A: Before you attempt creating Production orders, configure your
Order types- Transaction Code OPHJ
Order type Dependent parameters - Transaction Code OPL8
Backorder Scheduling - Transaction Code OMIH
Scheduling Levels - Transaction Code OMIF

M R P

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Q: We have an assembly 'A' using a subassembly 'B'. 'B' in turn uses raw material 'C'. Item 'A' is an MPS and is duly marked in Material Master. Item 'B' and 'C' are marked as 'PD'. When demand for 'A' is entered and MPS is run , upto which level the requirements are taken care of?
A: MRP can be run depending on your requirement. For example:

Single Item / Single Level from MPS - Transaction Code MD42 - Only the top MPS item ( 'A' in this case) is planned and dependent requirements will be passed to MRP item ( 'B' ) . Run MRP, Transaction MD02 on 'B' to plan it and all MRP items below .
Single Item / Multi Level from MPS - Transaction Code MD41 - All levels are planned - A , B & C
Total Planning from MPS online or background - Transaction Code MD40 or MDBS

Without marking the checkbox " Process MRP materials" is like case ( 1) above and with the checkbox marked is like case (2 ).

M R P

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Q: We want the system to run a single level MRP automatically on receipt of sales order. How to configure triggering event based MRP?
A: This can only be run if material master has planning strategy 41 (made-to-order) in the MRP2 view. We need to run for other MRP types. We have to create a user exit in the sales order processing (VA01) to start MRP based on data from our sales transaction.

M R P

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Q: What is the difference between "planned consumption" and "Unplanned consumption"? Can safety stock calculation be done on either of these?
A: While customizing movement types (OMJJ) it is defined as to which set of consumption values gets posted during the material movement. For some it may always be the total consumption and for some it is always the unplanned one and for some it is dependent on whether the issues were done with reference to a reservation ie., a planned consumption. The way these consumption values are taken into account in MRP is defined in the customizing of MRP types.
For Reorder point planning (VM) the total consumption is used to calculate the safety stock and the reorder point.
For Forecast based planning (VV) the total consumption is used to build the forecast which will be used to compile the order proposals.
For Deterministic MRP (PD) the unplanned consumption is used to calculate the forecast which in turn is added to the actual demand.

M R P

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Q: We have a lot size procedure here which is creating more order proposals. How do you set the limit value for maximum number of MRP order proposals per date in IMG?
A: Under customization, try materials management->consumption based planning->maintain all plants

Demand Management

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Q: Sales quantities in SOP for certain days are transferred into Demand Management and are shown as planned independent requirements. We need to keep the settings in SOP and change the periods in Demand Management? We would like to have a rolling horizon, for ex: the following 4 weeks on a daily basis, after that on a monthly basis. What is the best way to do this?
A: Use the automatic period split function.

Sales & Operations Planning

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Q: We defined SOP in months. However during SOP transfer to demand management, our independent requirements are appearing in weeks. How can we correct this from weeks into months ?
A: Check transaction OMPA for general split. OMPS - based on the MRP group. Ensure that MRP group assigned to the material. Delete any allocations in these tables. Then periods will be transferred to Demand Management with the same splits as in SOP. Also check whether the value of period is set as "month" at your plant level in Transaction 'OMP7'

Routing

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Q: We have deleted a group key in an operation in routing and the same does not appear for this routing (CA02). But we noticed that entries are maintained in table PLPO and the deletion indicator is not set. How does the system remember this deletion of group key?
A: You may look at the tables PLKO, MAPL and PLAS.

Routing

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Q: Scheduling times can be defined in the material master record by;
# entering the in-house production time. This value can be updated from the routing by the system.
# entering the setup, tear down, processing, and interoperation times. If these values are maintained, the system determines the in-house production time on the basis of lot size.
How do you get the system to update this value from the routing?
A: In routing, carry out scheduling. Go into the routing operation overview and follow Extras -> Scheduling -> Results. The pop-up window displays the scheduling data. At the bottom there is a pushbutton to copy the scheduling data to the material master Check this push button to update master data.

Routing

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Q: Can we use same routing for materials undergoing the same process/operations? Can we avoid separate routing for each and every material produced?
A1: Presume that there are 50 products and the fabrication shop uses a set of 10 machines. If all these products use the same settings of the machines, Reference Operation Sets (task list type S) can be setup for common processes that use the same work centers. However costing, scheduling and capacity will be affected if each product has different setup time and Reference Operation sets can not be used.
A routing for each material number ( type N or R) has to be set up and within that routing, the Reference Operation Set can be used.
However you can by try utilizing the KMAT material and product variants invariant configuration to avoid separate routing for each material.
A2: You may create a routing group. Go into routing creation and enter the plant and the group name. If you want you may name the group , else name is assigned by internal counter). Create the routing with the work centers, operation times, etc. Go to the "Header overview" screen and click on the "Mat Alloc" screen. Fill in the blanks with all the material masters that use this routing.

Work Centers

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Q: Can we have more than 6 standard values in standard value key?
A: One way to achieve this is to create another operation step using the same work center. However this shall be with a control key that is not a milestone. When the milestone operation is confirmed, the previous operations up to the next milestone are automatically confirmed. To get the desired number of standard values , all the 'non milestone' steps can be built depending on the need.

Bills Of Material

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Q: We have a BOM - 'A' with two packing materials 'X' and 'Y'. For 1000 units of 'A', 1 packing material of 'X' is required and for 50 units of 'A', 1 packing material of 'Y' is required. Base quantity of 'A' is defined as 1000. How can I define 'X' & 'Y' or in fact 'A'?
A: Make the base quantity of 'A' as 5000. The resulting component quantities would be 5 of 'X' and 100 of 'Y'.

PP Faqs

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Q: How to configure the planning calendar for the ATP calculation where goods are shipped every other working day?
A: Use Transaction MD25 and define calculation rule for every other working day. Check the lot size settings in OMI4 and maintain relevant data in MMR.

Q: We have two different production lines with different operations. One production line works 5 days a week and the other 7 days a week. The factory calendar is assigned to the plant for 5 days a week. This calendar is checked when MRP is run. How can we assign 5 day a week and 7 days a week against a factory calendar to the related resources? Is it possible to have two types of calendars?

A: Assign factory calendars to the work centers.

Q: What is the difference between by-product and co-product and how do you differentiate them in a BOM?
A: In case of Co-product costs are settled with a apportionment structure. In case of By-product the price of this by-product is credited to the order or the material stock account of the lead material being manufactured. Co-Product as well as by-product are defined as BOM Components/Items. Both of them have negative quantities. ( Not all negative quantity items fall under these categories!). When BOM is created for FERT , you can see one indicator in COMPONENT DETAILS screen for co-product. You need to define the co-products with this special indicator .

Q: What are some important tables used in PP ?

A: For orders:
CUAFVD dialog structure for order headers and items

AFPO - Order item
AFFLD Order: Dialog table for order sequences (AFFL)

MOPER Operation for production order
KBED Capacity requirements

AFRU Order completion confirmations
RESB Reservation/Dependent Requirements
AFFHD Structure of PRT's in orders
SOPER Sub-operations

SAFRU Sub-operation confirmations
SKBED Capacity requirements for sub-operation

MRP table is MDTB.
For PI:
CAUFV - AFVC Operation within an order

AFFT Order Process Instructions
AFFV Order process instruction values

Some other tables of interest:
PLKO, MAPL , PLAS.

Free download sap PP Books

2007-11-30T11:38:00.000+05:30

Sap PP (Production Planning) is used to plan and control the manufacturing activities of a company. This module includes; bills of material, routings, work centers, sales and operations planning, master production scheduling, material requirements planning, shop floor control, production orders, product costing, etc.

Here are some sap pp free ebooks download

Transactions

2007-11-30T11:09:00.000+05:30

search_sap_menu - Finds the menu path to a transaction - Can either type in TX code in the search criteria or a description- ie. 1st try SE38 and then ABAP.... the returned result is 'bottom to top'.

EDI Specific Transactions

VOE1 Translation between EDI categories and SD item categories
VOE2 Table EDSC view. Customer link to sales area detail
VOE3 Table view EDPVW. Add partner types that will be transferred to the IDoc
VOE4 Table view EDPAR. Link external partner number with our internal number
WEDI EDI Administrator Menu
BALE Idoc Administration

Scheduling agreements

OVA9 Create entries for each sold-to customer for which you will receive EDI schedule releases. At implementation, the only field that needs to be maintained is "Check PO number," which causes SAP to make sure that the PO number sent on the release matches the PO number on the schedule agreement. This transaction updates table T663A. SAP will not post an EDI schedule release, if this record is missing.
OVAI Create entries for each Vendor / Partner description combination. (Vendors must match sold-to Acct. at Cust., and Partner descriptions must match ship-to Partner descriptions.) This transaction updates table T661W. SAP uses this table to determine the schedule agreement sold-to partner.
OVAJ If you would like SAP to post schedule requirements using discrete dates only, instead of weekly and/or monthly buckets, you can indicate the days of the week that you deliver to this customer. SAP will divide the customer's quantity for a week or month evenly into the days of the week specified by the distribution function code. This code must be sent in the DELINS IDoc in field E1EDP16-ETVTF.

IDoc Transactions

WE09 / WE02 IDoc lists according to content. View IDocs via specific IDoc number or business application detail contained within the contents of a segment.
WE05 View IDocs
WE19 EDI test tool. Use to test inbound Function module changes.
WE20 Partner profile configuration. Add partner detail together with inbound and outbound relationships. We also incorporate message control on the outbound IDocs. Utilize the organizational units to trap functional errors for further processing
WE30 Create IDoc extension type
WE31 Segment create
WE57 Assign function module to logical message and IDoc type
WE60 IDoc type documentation tool
WE82 Link Release detail to Extension IDoc Type
BD55 Conversion rule user exit. Link conversion rule user exit to the different system \ partner combinations
BD87 Reprocess IDocs in error or waiting for action. (Both inbound and outbound in 4.6. Use BD88 in prior versions)
BALA ALE Application Distribution
BALM ALE Master Data Distribution

Output determination

856 - ASN

V/36 Maintain output determination for deliveries (Output determination procedures). V10000 (Header output) has condition type LAVA (usually with requirement 1 NB: Use V/84 – V7ALLE – SHAD for grouped ASNs. I.e. Group deliveries into shipments
VV21,VV22,VV23 Create output condition records for shipping. LAVA – WE (Partner function) - We must add each new partner with VV21
VL71 Reissue output for deliveries

810 - Invoice

V/54 Maintain access sequence for billing documents
VV31,VV32,VV33 Create condition records for billing documents. (RD00 – RE Billing party)
VF31 Reissue output for billing documents

855 – Order Response

V/30 Sales document output types (BA00)
V/48, V/32, V/43 Maintain access sequence for sales documents
VV11,VV12,VV13 Create condition records for sales documents. (BA00 – SP Sold to party)

Requirements coding

V/27 Create code to check requirements for output control. Used to check ZBA0 against BA00 output.

Sales & Distribution

Sales order / Quote / Sched Agreement / Contract

VA02 Sales order change
VA05 List of sales orders
VA22 Quotation change
VA32 Scheduling agreement change
VA42 Contract change

Billing

VF02 Change billing document
VF11 Cancel Billing document
VF04 Billing due list
FBL5N Display Customer invoices by line
FBL1N Display Vendor invoices by line

Delivery

VL02N Change delivery document
VL04 Delivery due list
VKM5 List of deliveries
VL06G List of outbound deliveries for goods issue
VL06P List of outbound deliveries for picking
VL09 Cancel goods issue
VT02N Change shipment
VT70 Output for shipments

General

VKM3, VKM4 List of sales documents
VKM1 List of blocked SD documents
VD52 Material Determination

Workflow

SWEAD Event queue administration
SWE2 Event type linkages
SWE3 Event linkages
PPOME Organizational Unit Maintenance
SWE5 Consistency Checks for Event Linkages
SWUD Workflow Diagnostic Tool

General

The following section provides detail on other useful SAP areas.

Create delivery via transfer orders

Once the order is saved proceed through the following steps. The process assumes the item has values in the warehouse bin.

VL04 Delivery due list. Run the delivery due with your order number to create the delivery
LT03 Create Transfer Order. EG. Warehouse: 101 and enter. Picking background. Save

The Transfer order should now be saved. It now needs to be confirmed.
In LT03 go to menu option Transfer Order -> Confirm – Transfer Order
Enter
Save
The transfer order is now confirmed.

VL02N Delivery change. EG: Edit the delivery to do the following Pack – External customer material number = COO. External delivery number – Waybill number. BOL – Transport tag. Carrier – Header partner – SP (E.G. FXP). Tracking number = Packing Unit

Purchase Orders

ME22N PO Change
ME57 Create PO from purchase requisition

ATP

CO09 Availability overview

Goods Movement

MIGO Post goods receipt
MB51 Material document list
MB01 Goods Movement

Other

MD04 Material Requirements. Shows material requirements and releases against materials
SE38 ABAP Editor. Used to modify ABAP programs
SM01 Transaction list. Lock transactions in the system. Also a good tool to see what transactions are available
SHDB Transaction recorder (BDC)
CMOD User exit \ project tool. Coordinates your changes into projects for the purpose of activating all user exits for a particular project. A user exit needs to be modified before it will work
SE16 Table contents display
SOST View mails sent externally from SAP
SU53 Check authorization object
SQVI Table Quickviewer – Used to created quick client dependent reports
ST22 ABAP Dump Analysis
ST01 System trace
ST11 Display developer trace
ST05 SQL Trace
SM21 System log
ST22 Display short dumps
SM12 Display locked entries

Programs

List of ABAP Reports

Idoc

RBDAPP01 Post inbound Idocs to application documents
RBDAGAI2 Re-processing of IDocs after ALE input error
RBDAGAIE Reprocessing of edited IDocs
RBDMANIN Start error handling for non-posted Idocs
RSEINB00 Idoc inbound processing by file
RSEOUT00 Process outbound IDocs

General

RV80HGEN Report 'RV80HGEN' for including customer-specific routines in the SAP standard source code is not included automatically as an XPRA in the object list of the transport request. See OSS note 0385067. This report needs to be run in target clients once you have implemented a custom requirements definition.
RSWUWFML Report that interrogates the Workflow inbox, based on certain selections, and then forwards a notification to the respective users that they have email waiting in the SAP system. The auto-forwarding assignment of an email address to a user can be accomplished by the administrator and tx: SO36 or by the user themselves using tx: SO13. Use tx: SOST to view email status’ sent from SAP.
RHSOBJCH Corrects the following error in workflow customizing:

Transport object PDST

Information Table SOBJ is consistent as regards key tables

***Error*** Table HRP1600 Not an entry in table SOBJ

Information Table SOBJ is consistent as regards PAD tables

See note 134311 (point 2). Note 60801 also recommends the same steps regarding RHSOBJCH.

RSPO0075 Run report RSPO0075 to activate access method M for device types.

All Tables

2007-11-30T11:08:00.000+05:30

Production Planning Tables

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Thanks to Tymon Kerste for the PP table info. Thanks to Tymon Kerste for the PP table info.

MAST	Material BOM
STKO	BOM Header
STPO	BOM Positions (detail)
MAPL	Assignment fo Task Lists to Materials
PLKO	Routing Group Header
PLSO	Routing Group Sequence
PLPO	Routing Group Operations
AFKO	Production Order Header
AFPO	Production Order Position (details)

Books

2007-11-30T11:04:00.002+05:30

Production Plannning and Control with SAP
Administering SAP R/3: The Production and Planning Modules
SAP MM / PP Interview Questions, Answers, and Explanations: SAP Production Planning Certification

Subcontracting In SAP in PP

2007-11-30T11:04:00.001+05:30

Below are the steps of subcontracting:

1. For a production material (1001), one raw material (2001) is assigned.

2. Production process of 1001 is having four operations 10, 20, 30 and 40.

3. In this 10, 30, and 40 are internal operations and 20 is external operation (sub-contracting).

4. To address this, we created a dummy material (non-valuated) and named as 1001-20 (Finished product number + Operation to be performed).

5. This 1001-20 should form part of the component in BOM of 1001. That is BOM of 1001 will have components as raw material 2001 and this dummy material 1001-20. In routing, assign this dummy material 1001-20 to operation 20.

6. During BOM creation, you should remove costing relevancy for the item 1001-20.

7. In routing, operation 20 is created with a work center (which is external operation work center) with exteranl operation control key.

8. In operation details, for external processing, assign the info record of external processing.

9. Info record of external processing has to be created for vendor with relevance to the operation to be performed externally with vendor. (We are using material group field in the external processing in routing operation).

10. When create production order with above set up, system will create Purcha Req for external operation. This has to be converted to purchase order.

11. Now, this dummy material should be kept as 5000 or 6000 in stock using 561. When Purchase order is raised, required quantity has to be moved to vendor using 541. When we do goods receipt the stock with vendor shall come down. With this, we can monitor the material (with dummy material number) stock with vendor (please note we can see only quantity and not value) .

12. When we do GR for external purch order, we receive only the operation performed. (So, coversion cost to vendor shall be paid).

13. After ensuring GR is done, order confirmatin of operation 0020 has to be done. (here we capture the quanttiy and also the valuation of material in production order).

Collective Confirmations in Repeatitive Manufacturing in PP

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This setting is done in tcode: SPRO

The path is as follows;

Production - Shop Floor Control - Confirmation - Define time for confirmation processes.

Here we can determine whether we want to do the backflushing, goods receipt and cost calculations immediately on confirmation, as a background process or as an update.

Define Time for Confirmation Processes - Define control keys that specify when confirmation processes run. You must specify the order category for the control key (10 PP production order, 20 network, 30 maintenance order, 40 process order).

You can specify the execution time for the following confirmation processes:
- automatic goods receipt
- backflushing
- determination of actual costs

As execution times the following are available:
- at once online
- at once as an update
- later in the background

The standard settings set is that there are no control profiles. That means that all confirmation processes run online.

Do the following if you want to improve performance in the area of confirmations.
1. Create a control key.
2. Assign the control key to the desired order type by entering it in the confirmation parameters for the order type in the field process control.
3. Make sure that the parallelization type is defined for the processes that you want to parallelize.
4. Plan the background job for confirmation processes (Program name: CORUPROC). You can create variants for the individual confirmation processes.

What Transaction to Perform Discontinued Parts in PP

2007-11-30T11:03:00.001+05:30

In industry we need to replace on part by another material. this due to the following reason:

New safety regulations come into force on a certain date. Therefore, a specific component must be discontinued as it no longer complies with the safety regulations, or an expensive part is to be replaced by another cheaper part.

Therefore, the aim of the 'discontinued parts' procedure is to replace one component by another component at a certain point in time. This means that the dependent requirements for the current component are to be reassigned to another part (the follow-up
material), once you have exhausted the stocks of the current material.

The material that is to be discontinued must be defined as a part to be discontinued in the material master record.

Go to MM02 in MRP 4 view click on discontinued part checkbox.
Then entre the new material and date from which the new materil is to be taken in planning.

A distinction is made whether;
a) exactly one material is to be replaced by one follow-up material (simple discontinuation), or whether
b) a group of materials are to be replaced by another group of materials (parallel discontinuation)

Inspection Characteristics Indicator in the Control Key in PP

2007-11-30T11:02:00.000+05:30

In control key defination there is an option to tick indicator insp-chr-required.
What would be the subsequent result of choosing this indicator?

This scenario is for PP-QM interface

With this indicator you can record the results for that Production order - Operation combination.
But the pre-requsits are you need inspection Characteristics in routing & 03 type must be active for that material

Then the scenario become as

Planned order (PP Fuct) ---- Production order (PP Fuct) --- Prod order rel (PP Fuct)
----- Inspection lot generated (QM Fuct) ---- Result recording for that opeartion
(QM Fuct) --- Accept lot (QM fuct) ---- Confirm Prod Order ( PP fuct) ---- GR for production order.

Indicator: inspection characteristics for operation required
This indicator specifies that inspection characteristics are to be maintained for the following objects if specified in the control key you selected:

Operations in Quality Management (QM) and Production Planning (PP)
The system ignores this indicator if it is set for sub-operations. For operations and phases in Production Planning for Process Industries (PP-PI)
The system ignores this indicator if it is set for secondary resources.
The system ignores this indicator in Plant Maintenance (PM).
In the following situations, the consistency check for the task list generates a warning message:

If you set the indicator in the control key but have not maintained inspection characteristics for the operation or phase if you have not set the indicator in the control key but have maintained inspection characteristics for the operation or phase

Dependencies
Operations and phases, in which this indicator is set in the control key, are included in the QM work lists for inspection results recording.

If you use this indicator then you should:
1-assign MICs in this operation
2-and then you can make inprocess inspection
3- record result for this operation every specified time or quantity produced (using inspection points )
4- u can also get charts for ur operation such as control chart to get an idea about the capability of the process
*each step want some details

Scrap Management in Finished Product in PP

2007-11-30T11:01:00.002+05:30

Can anybody tell me that how I will manage scrapped finished product.
For e.g, If I already entered operational scrap and component scrap percentage at the required fields.
Let us say, planning is of 250 pcs., as we have put some percentage of scrap so the planning is of 270 pcs.
But in actual production 255 are correct and 15 are defective.
So where I will keep the record of these defective pcs. and how I will plan for reworking of these defective items.
Also , if I want a report that during on date (x), in shift (y) how much were scrap or defective item, how I will get?

Why are you not using by-product and confirm the production under 531 movement. In this way you find everything against material code.

Sanjay

In order confiramtion screen, you can put the quantity which is ok. Rest of the qty you will have to enter in rework or scrap qty. But, alone entry in this field will give only information that how much qty is rejected or to be reworked.You will have to make an additional GR for scrapped qty,stating it in the code of scrap. If you want to rework, then make a new rework order of the qty not confirmed in prodn order.

You can also have a trigger point, in order confirmation screen which will trigger new rework order or generation of scrap if you entered any qty in respective fields.

I think this can solve your problem.

Mahendra

It is not correct to put scrap % for all materials. This is to be used only in case of fix rejection which is by virtue of process e.g. molding casts, sheet metal, pipes, gaskets, lids etc.

It is better to use 531 movement if it is a single component e.g. casting by putting the scrap quantity.

Please note that if those can be reworked then you shall use quality module e.g. Final Assembly (entire final assembly never gets scrapped). So that product will go in quality & then accept the OK quantity & reject rework. After reworking accept those parts. Alternately for recording rework use rework orders.

Best way to scrap material is manually post actual rejection using 551-movement separately.

Prasad Indapwar

You have take the help of Quality management in which you have to create lot for each production shift wise and aganinst each lot you have to record good, diffective stocks you will get total MIS.

Meaning of Costing Variant in SAP PP

2007-11-30T11:01:00.001+05:30

Can anybody pls tell me what a costing variant means in PP.

A tool that contains all control parameters for costing, including parameters that control how cost estimates are executed and the material prices or activity prices that are used to valuate the costing items.

In material costing (costing with and without quantity structure), the costing variant determines the following:

- The purpose of the cost estimate (costing type)

The prices that are selected to valuate the quantity structure and calculate overhead expenses (valuation variant)

The dates that apply to the actual cost estimate and to the explosion and valuation of the quantity structure (date control)

How the BOMs and routings are selected to create the quantity structure (quantity structure control; only relevant for cost estimates with a quantity structure)

The strategy by which the SAP System looks for costing data from other cost estimates (transfer control)

In unit costing (base object costing and unit costing for orders), the costing variant determines the following:

- The purpose of the cost estimate (costing type)

The prices that are selected to valuate the costing items (valuation variant)

Whether the individual costing items are assigned to cost elements

In Easy Cost Planning, the costing variant determines the following:

- The purpose of the cost estimate (costing type)

The prices that are selected to valuate the costing items (valuation variant)

For internal orders, work breakdown structure (WBS) elements, and ad hoc cost estimates, the dates that apply to the cost estimate (date control). For WBS elements, the dates can be overridden by the dates of the WBS element.

You define costing variants in Customizing for the appropriate application component.

Same serial number assigned to several production orders in PP

2007-11-30T11:00:00.002+05:30

We had made active serial number managment. During production creation we are assigning a serial number to the production order. System allows to assign the same serial number to the another production order also.

I have refered to the SAP note 647188 which gives solution like this:
When a serial number is assigned to a production order, a system status transaction (PMP1) is used - when the assignment is deleted, PMP2 is processed. Thus, it is possible to define a user status (which forbids a second assignment) and set it for the assignment.

Can anybody tell me what is PMP1 and PMP2? and how to implement this. I am not able find any info regarding this.

-------------------------------

=== Though I cannot test and confirm, you can try the below procedure:

(1) Create a User Status Profile (or use an Existing one) with Equipment as the Object Type with 2 User Statuses: Order Assigned and Assignment Deleted

(2) For the User Status: Order Assigned
Select Forbidden (Influence) and Set (Next Action) as the Transaction Control for the Business
Transaction PP Order Assignment
Select Forbidden (Influence) and Set (Next Action) as the Transaction Control for the Business
Transaction PP Order Assignment

(3) For the User Status: Assignment Deleted
Select Forbidden (Influence) and Set (Next Action) as the Transaction Control for the Business
Transaction PP Order Assignment
Select No Influence (Influence) and Set (Next Action) as the Transaction Control for the Business
Transaction Cancel assignment to PP order

(4) Assign the above Status Profile to the Equipment Category being used by You

Question : Subject : Basic dates history in production order

2007-11-30T11:00:00.001+05:30

Hi,

there is a table where are recorded modification to basic dates in production order?

Thanks

Answer : Subject : Basic dates history in production order

Hi,

Is that PLAF that you means?It contains basic date and quanity for a planned order.
Regards.

Answer : Subject : Basic dates history in production order

Hello,

For a production order, basic dates are available in AFKO table..
But, it looks like you are looking for the history of all the changes made to the basic dates.
Please check table HIKO. I think you will have to go for order change management (OCM) for that. We donot have OCM here and HIKO table is empty. Please let me know if it is correct..

Regards

Answer : Subject : Basic dates history in production order

Hi,
I've checked : also our HIKO is empty and in effect OCM has not been implemented.

Thank you very much for your help.

Regards

Mass Processing for Production Order in PP

2007-11-30T10:59:00.002+05:30

4.6x

If you need a mass closing or technical complete for your production orders. This transaction will be great.

CORM - Mass processing for Orders

Change Production Order - CO02 in PP

2007-11-30T10:59:00.001+05:30

4.6c
Msg C7038 - Schedule conflict:Constraint is too late

In the order XXXXXX the operation 80 and 90 are partially confirmed with the following actual date:

Operation 80 actual start: 24.07.XXXX 21:39.23
Operation 90 actual start: 26.07.XXXX 07:22.15

For the partiall confirmed operation, the remaining duration is scheduled after the confirmed atual date. This mean, that the program schedule for the operations 80 and 90 forward, even though "backward- scheduling" is set for the order.

The program calculate that the operation should finish at 26.07.XXXX 12:35.49, it is greater than the actual start date of the
operation 90 26.07.XXXX 07:22.15. And the operation 90 is the successor of the operation 80. So is the actual date of the operation 80 (24.07.XXXX 21:39.23) too late, this constraint is the cause of the conflict.

You can set the scheduling indicator "shift order", and you can get rid of this problem.

CO02 - Order -> Settings - Scheduling parameters -> Tick Shift order

Default for all newly created orders. (Plant dependant)
OPU3 - Define Scheduling Parameters for Production Orders.

Production Order Status in PP

2007-11-30T10:58:00.002+05:30

The prerequisite to DLFL an order is that the cost balance is zero. This can be achieved either by not posting any activity to
the order, or by settling the cost. Settlement can only occur once the order has been received into stock (DLV), so if there is a
problem TECO is used to override that prerequisite.

In short. TECO is not needed to DLFL an order. It is only needed if you want the order to settle and eventually archive
because you do not have the status DLV (received into stock).

Production order status table

System Status Management is a central function for all modules, not only logistics but financial modules too. Wherever you have the system status management, which is, you have the system statuses:

CRTD - Created,
REL - Released,
PCNF - Partially Confirmed,
CNF - Confirmed,
PDLV - Partially Delivered
DLV - Delivered
etc...

System stores these object statuses at the JEST table. In this table, Object ID (field OBJNR) is the key. And every object has different number ranges for the Object ID, which is automatically given by the system.

Examples for PP are,
when you create a production order, you can see the System statuses at:
1. Order header
2. Order operations
3. Order components.

As you may already know, Order header data is in table AUFK, Order operations data is in table AFVC, and Order components data is in table RESB.

If you check these tables, you will see the Object Number field in these tables, with prefixes OR for header, OV for operations and OK for components.

For example:
1. If I have the "order number" 1000102, in table AUFK, I will have the Object number OR000001000102. (because length of order number data type is 12 chars, leading zeros are added by system)

2. If the "Routing number of operations in the order" is 83 and the Operation counter number is 1 for an order operation, in table AFVC, I will have the object number OV000000008300000001. (because length of "Routing number of operations in the order" data type is 10 chars, and length of Operation coounter number data type is 8 chars, leading zeros are added by system accordingly.)

3. If the Reservation number is 139 and Reservation item number is 1 for an order component, in table RESB, I will have the object number OK00000001390001. (because length of Reservation number data type is 10 chars, and length of Reservation item number data type is 4 chars, leading zeros are added by system accordingly.)

Now I can check the table JEST with these keys and I can get the statuses for my order header, operations or components.

If you want statuses of an order:
1. Find the Header object number in table AUFK, using order number. (or alternatively you can just add OR to the order number)
2. Go to table JEST with the Header object number.

If you want statuses of an order component:
1. Find the Reservation number(RSNUM) of the order at table AFKO, using order number.
2. Find the Reservation item number of the component at table RESB using reservation number. And get the Object number of the component.
3. Go to table JEST with the Component object number.

If you want statuses of an order operation:
1. Find the "Routing number of operations in the order"(AUFPL) of the order at table AFKO, using order number.
2. Find the Operation counter number of the operation at table AFVC using "Routing number of operations in the order". And get the Object number of the operation.
3. Go to table JEST with the Operation object number.

Note: Bear in mind that the statuses you will find in table JEST also has another field "Indicator: Status Is Inactive", which states that the object had the status before, but it is inactive at the moment.

For example:
When you first create a production order, it will have the status (I0001 - CRTD - Created) in table JEST. And it won't have any entry in table JEST for the status (I0002 - FREI - Released).

When you release the order, it will have both CRTD and FREI statuses, but the CRTD status will be marked Inactive. Because, when you run the Release process for a production order, it will Activate the FREI status (create entry in JEST) and Deactivate the CRTD status (modify th entry in JEST and change the "Indicator: Status Is Inactive" field).

Control whether the Production Order operations will be printed in PP

2007-11-30T10:58:00.001+05:30

CO02
click Operations button
tick the Operations you want and click the General button

the field No. completion slips 0 - no printing of confirmation slips

Control parameters for production order conversion from planned order in pp

2007-11-30T10:57:00.003+05:30

OPKP - Profile shop floor control
Whether to auto release the production order once it is converted.

The definition for the control is specify via Material Master - Work Scheduling View
Field -> Production Schedule Profile

Print Shop Papers - Configure new / existing SAP Printers in PP

2007-11-30T10:57:00.001+05:30

SAP control the printing of shop floor papers by SAP users name.

Do not be alarm if you get an error message stating that the print form was not found. The SAP users name have not been configure to print the shop floor papers.

If you want to use a new shop floor papers you first have to design a new :-

1. Layout set
Copy the standard layout set as a reference (for example PSFC_STD_LAYOUT) to a e.g. ZPSFC_STD_LAY01.

2. Write a new print report
Copy the print program that belongs to the standard layout set (for example, PSFCCONF) to a e.g ZPSFCCONF01.

Steps to configure the Print Shop Papers :-

Transaction OPK8

To add-in an additional users to print the shop papers :-

Click the Spool parameters for user

Double click on the user name that are allowed to print the shop papers.
Here you tick on the Print column the Print Shop Paper Layout that will be used. You can specify the default printer if you want. To print immediately, just tick the Immed. column.

To modify the existing Layout sets :-

Click the Reference Order Type

Next Select the Production Order type by clicking the button next to the Production Order type.
Next Click the Form on the left screen
Here you specify the Layout Sets that will be used.

To modify the existing Program control for the Layout sets :-

Click the Reference Order Type

Next Select the Production Order type by clicking the button next to the Production Order type.
Next Click the Print programs on the left screen
Here you specify the program the will be used to print the Layout Sets.

The control is by RefOrType, List and Report Name

COGI - Keep track of all the back flushing failure during production confirmation in PP

2007-11-30T10:56:00.001+05:30

Reasons for failed back flushed:-

Storage Location not specified
Shortage of quantity
Period close - happened during beginning of month

Search for Open Production Order in PP

2007-11-30T10:55:00.002+05:30

CO28 - Order Information System

call transaction CO28 - default -> Order header -> hit enter
Key in Profile -> 000001 - Standard profile
System Status -> CNF tick Excl. DLV tick Excl. (exclude production order with this 2 status)
You can fill in other selection criteria such as Plant to filter away more data
Finally, click execute and the result will be display.

CO26 - Order Information System Object List
If you want to display a tree structure of the production order. e.g.
Orders
Order
xxx xxx xxx
Item
xxx xxx xxx
Components
xxx xxx xxx
Materials
xxx xxx xxx

call transaction CO26 then click the Object button to select your desired tree data
Key in Overall Profile -> 000000000001 - Standard profile
System Status -> CNF tick Excl. DLV tick Excl. (exclude production order with this 2 status)
You can fill in other selection criteria such as Plant to filter away more data
Finally, hit enter and the result will be display.

If you need more system status, you can configure it using transaction code BS42 (4.6c). - Status Selection Schema. The field will be shown as Selection Profile Status.

e.g. to exclude all
Status not
DLV Tick
and CNF Tick
and DLFL Tick

Configure a New Production Order Type in PP

2007-11-30T10:55:00.001+05:30

As the business progress and expand, there will be a need to create new production type so as to track the different type of production order that have been created. For e.g. your company may want to know what how many rework order, prototype order or other order types have been created in the SAP system.

Create New SAP Production Order Type

4.6c

OPJH - Maintain Production Order Types

Assign Plant to New Order Type

OPL8 - Order Type-Dependent Parameters
OPJK - Define Checking Control
OPK4 - Parameters for Order Confirmations (this will determine whether confirmation is allow for this Order Type)
OPU3 - Define Scheduling Parameters for Production Orders

Sample ABAP on Multi-Level Bom with Location Balance

2007-11-30T10:39:00.002+05:30

REPORT ZMULTIBOM NO STANDARD PAGE HEADING LINE-SIZE 195
LINE-COUNT 60(2) MESSAGE-ID Z1.

TABLES: MBEW, "Material Valuation
MSLB, "Special stocks with vendor
MARA, "Material Master
MAKT, "Material Descriptions
MARD, "Material Master: Storage Location/Batch Segment
MAST, "BOM Header
STKO, "BOM Detail
STPO, "Bom Components
STAS. "BOM Alternative

* Text Elements
* Plant
SELECT-OPTIONS: S_WERKS FOR MAST-WERKS DEFAULT 'CA',
* Material
S_MATNR FOR MAST-MATNR,
* Material Type
S_MTART FOR MARA-MTART.
* Base Quantity
PARAMETERS: S_BASE TYPE I DEFAULT '1'.
* Display up to Level
PARAMETERS: S_LVL TYPE I DEFAULT '99'.
SELECTION-SCREEN SKIP.
* Include Vendor Stock
PARAMETERS: X_MSLB AS CHECKBOX.

DATA: W_MATNR LIKE MAPL-MATNR.

DATA: PARENT-MATNR LIKE MAST-MATNR,
CHILD-MATNR LIKE STPO-IDNRK,
CHILD-WERKS LIKE MAST-WERKS,
CHILD-STLAL LIKE MAST-STLAL,
W_MAKTX LIKE MAKT-MAKTX,
W_STD TYPE P DECIMALS 5,
W_MAV TYPE P DECIMALS 5,
W_MENGE TYPE P DECIMALS 3,
W_LEVEL TYPE I,
W_DOT(1),
W_LVL(12),
W_LVL1(12),
W_LVL2(2),
W_COL TYPE I,
W_LFLAG,
W_TTL LIKE MARD-LABST.

DATA: BEGIN OF INT1 OCCURS 50,
LGORT(6),
LABST LIKE MARD-LABST,
END OF INT1.

IF S_BASE EQ 0.
S_BASE = 1.
ENDIF.

** append multi level routing
SELECT * FROM MAST WHERE WERKS IN S_WERKS AND
MATNR IN S_MATNR.
SELECT SINGLE * FROM MARA WHERE MATNR = MAST-MATNR AND
MTART IN S_MTART.
IF SY-SUBRC NE 0.
CONTINUE.
ENDIF.
IF MARA-LVORM <> 'X'.
PARENT-MATNR = MAST-MATNR.
CHILD-MATNR = MAST-MATNR.
CHILD-WERKS = MAST-WERKS.
CHILD-STLAL = MAST-STLAL.
SELECT SINGLE * FROM MAKT WHERE MATNR = MAST-MATNR AND
SPRAS = 'E'.
W_MAKTX = MAKT-MAKTX.
REFRESH INT1.
SELECT * FROM MARD WHERE MATNR = MAST-MATNR AND
WERKS = MAST-WERKS AND
LABST NE 0.
MOVE MARD-LGORT TO INT1-LGORT.
MOVE MARD-LABST TO INT1-LABST.
APPEND INT1.
ENDSELECT.
IF X_MSLB EQ 'X'.
SELECT * FROM MSLB WHERE MATNR EQ MAST-MATNR AND
WERKS EQ MAST-WERKS AND
LBLAB NE 0.
MOVE MSLB-LIFNR TO INT1-LGORT.
MOVE MSLB-LBLAB TO INT1-LABST.
APPEND INT1.
ENDSELECT.
ENDIF.
W_LEVEL = 1.
NEW-PAGE.
PERFORM GETCHILD.
ENDIF.
ENDSELECT.

** get child parts
FORM GETCHILD.
SELECT * FROM STPO WHERE STLNR = MAST-STLNR
ORDER BY POSNR.
SELECT SINGLE * FROM STKO WHERE STLNR = STPO-STLNR
AND STLAL = MAST-STLAL.
SELECT SINGLE * FROM STAS WHERE STLNR = STPO-STLNR AND
STLKN = STPO-STLKN AND
STLAL = MAST-STLAL.
IF SY-SUBRC EQ 0.
CLEAR: W_DOT, W_LVL, W_LVL1.
PERFORM WRT_DTL.
CHILD-MATNR = STPO-IDNRK.
W_LEVEL = W_LEVEL + 1.
IF W_LEVEL <= S_LVL.
PERFORM SUBCHILD.
ENDIF.
W_LEVEL = W_LEVEL - 1.
ENDIF.
ENDSELECT.
ENDFORM.

** get grand children parts
FORM SUBCHILD.
SELECT SINGLE * FROM MAST WHERE MATNR = CHILD-MATNR
AND WERKS = CHILD-WERKS.
IF SY-SUBRC NE 0.
EXIT.
ENDIF.
SELECT * FROM STPO WHERE STLNR = MAST-STLNR
ORDER BY POSNR.
SELECT SINGLE * FROM STKO WHERE STLNR = STPO-STLNR AND
STLAL = MAST-STLAL.
SELECT SINGLE * FROM STAS WHERE STLNR = STPO-STLNR AND
STLKN = STPO-STLKN AND
STLAL = STKO-STLAL.
IF SY-SUBRC EQ 0.
W_DOT = '.'.
PERFORM WRT_DTL.
CHILD-MATNR = STPO-IDNRK.
W_LEVEL = W_LEVEL + 1.
IF W_LEVEL <= S_LVL.
PERFORM SUBCHILD.
ENDIF.
W_LEVEL = W_LEVEL - 1.
SHIFT W_LVL.
ENDIF.
ENDSELECT.
ENDFORM.

TOP-OF-PAGE.
WRITE:/ SY-DATUM,SY-UZEIT,
85 'ABC PTE LTD',
182 'Page', SY-PAGNO.
WRITE: / SY-REPID,
75 'BOM STRUCTURE (WITH LOCATION BALANCES)',
182 SY-UNAME.
SKIP.
CLEAR W_LFLAG.
WRITE:/ 'Material No.:', PARENT-MATNR,
60 'Plant :', MAST-WERKS.
W_COL = 90.
CLEAR W_TTL.
LOOP AT INT1.
IF W_COL > 195.
IF W_LFLAG IS INITIAL.
WRITE:/ 'Description :', W_MAKTX,
60 'Base Qty :', S_BASE LEFT-JUSTIFIED.
W_LFLAG = 'X'.
W_COL = 90.
ELSE.
W_COL = 90.
SKIP.
ENDIF.
ENDIF.
WRITE AT W_COL 'Loc :'.
W_COL = W_COL + 6.
WRITE AT W_COL INT1-LGORT.
W_COL = W_COL + 7.
WRITE AT W_COL(12) INT1-LABST LEFT-JUSTIFIED.
W_COL = W_COL + 16.
W_TTL = W_TTL + INT1-LABST.
ENDLOOP.
IF W_LFLAG IS INITIAL.
WRITE:/ 'Description :', W_MAKTX,
60 'Base Qty :', S_BASE LEFT-JUSTIFIED,
90 'Total :', W_TTL LEFT-JUSTIFIED.
ELSE.
WRITE AT W_COL 'Total :'.
W_COL = W_COL + 8.
WRITE AT W_COL W_TTL LEFT-JUSTIFIED.
ENDIF.
SKIP.
ULINE.
WRITE: /001 'Level',
011 'Item',
017 'Component',
037 'Description',
079 ' Per',
089 'UOM',
094 ' Std Price',
106 'Moving Avg',
119 'Location',
128 ' Balance',
139 'Location',
148 ' Balance',
159 'Location',
168 ' Balance',
179 'Total Quantity'.
ULINE.

FORM WRT_DTL.
CLEAR: MAKT-MAKTX, W_MAV, W_STD.
SELECT SINGLE * FROM MAKT WHERE MATNR = STPO-IDNRK AND
SPRAS = 'E'.
SELECT SINGLE * FROM MBEW WHERE MATNR = STPO-IDNRK AND
BWKEY = MAST-WERKS.
IF SY-SUBRC = 0.
W_MAV = MBEW-VERPR / MBEW-PEINH.
W_STD = MBEW-STPRS / MBEW-PEINH.
ENDIF.
W_MENGE = ( STPO-MENGE / STKO-BMENG ) * S_BASE.
W_LVL2 = W_LEVEL.
CONCATENATE W_DOT W_LVL INTO W_LVL.
CONCATENATE W_LVL W_LVL2 INTO W_LVL1.
WRITE: /001 W_LVL1,
011 STPO-POSNR,
017 STPO-IDNRK,
037 MAKT-MAKTX,
079(8) W_MENGE,
089 STPO-MEINS,
094(10) W_STD,
106(10) W_MAV.
W_COL = 119.
CLEAR W_TTL.
SELECT * FROM MARD WHERE MATNR = STPO-IDNRK AND
WERKS = MAST-WERKS AND
LABST NE 0.
IF W_COL > 166.
W_COL = 119.
WRITE AT /W_COL ' '.
ENDIF.
WRITE AT W_COL MARD-LGORT.
W_COL = W_COL + 5.
WRITE AT W_COL(13) MARD-LABST.
W_COL = W_COL + 15.
W_TTL = W_TTL + MARD-LABST.
ENDSELECT.
IF X_MSLB EQ 'X'.
SELECT * FROM MSLB WHERE MATNR = STPO-IDNRK AND
WERKS = MAST-WERKS AND
LBLAB NE 0.
IF W_COL > 166.
W_COL = 119.
WRITE AT /W_COL ' '.
ENDIF.
WRITE AT W_COL(6) MSLB-LIFNR.
W_COL = W_COL + 6.
WRITE AT W_COL(12) MSLB-LBLAB.
W_COL = W_COL + 14.
W_TTL = W_TTL + MSLB-LBLAB.
ENDSELECT.
ENDIF.
WRITE AT 179(15) W_TTL.
ENDFORM.

Writing a Multi-Level BOM Cost Roll-up with ABAP

2007-11-30T10:39:00.001+05:30

REPORT ZBOMCOST NO STANDARD PAGE HEADING LINE-SIZE 195
LINE-COUNT 60(2) MESSAGE-ID Z1.

TABLES: MBEW,
MAPL,
PLPO,
PLAS,
CRHD,
CRCO,
CSSL,
COST,
EINE,
EINA,
MARA, "Material Master
MAKT,
MARC,
MAST, "BOM Header
STKO, "BOM Detail
STPO, "Bom Components
STAS. "BOM Alternative

SELECT-OPTIONS: S_WERKS FOR MAST-WERKS,
S_MATNR FOR MAST-MATNR,
S_MTART FOR MARA-MTART.

PARAMETERS: XBASE TYPE I DEFAULT '2000'.

DATA: W_MATNR LIKE MAPL-MATNR.

DATA: S_BASE TYPE I,
PARENT-MATNR LIKE MAST-MATNR,
CHILD-MATNR LIKE STPO-IDNRK,
CHILD-WERKS LIKE MAST-WERKS,
CHILD-STLAL LIKE MAST-STLAL,
W_MAKTX LIKE MAKT-MAKTX,
W_STD TYPE P DECIMALS 5,
W_MAV TYPE P DECIMALS 5,
W_MENGE TYPE P DECIMALS 3,
W_LEVEL TYPE I,
W_DOT(1),
W_LVL(12),
W_LVL1(12),
W_LVL2(2),
W_COL TYPE I,
W_LFLAG,
W_TTL LIKE MARD-LABST,
WCNT TYPE I.

DATA: WCONV TYPE P DECIMALS 5,
WCOST TYPE P DECIMALS 5,
WUCOST TYPE P DECIMALS 5,
WOHCOST TYPE P DECIMALS 5,
WEXCOST TYPE P DECIMALS 5,
WMCOST TYPE P DECIMALS 5,
WTCOST TYPE P DECIMALS 5.

DATA: WLAR LIKE PLPO-LAR01,
WVGW LIKE PLPO-VGW01,
WVGE LIKE PLPO-VGE01.

DATA: BEGIN OF ITAB OCCURS 100,
CNT TYPE I,
LEVEL TYPE I,
LVL1 LIKE W_LVL1,
WERKS LIKE MAST-WERKS,
POSNR LIKE STPO-POSNR,
IDNRK LIKE STPO-IDNRK,
MENGE TYPE P DECIMALS 5, " req qty
MEINS LIKE STPO-MEINS,
END OF ITAB.

DATA: BEGIN OF ITAB1 OCCURS 100,
WERKS LIKE MAST-WERKS,
IDNRK LIKE STPO-IDNRK,
UCOST TYPE P DECIMALS 5,
* mcost type p decimals 5,
* ohcost type p decimals 5,
* excost type p decimals 5,
END OF ITAB1.

DATA: BEGIN OF ITAB2 OCCURS 100,
CNT TYPE I,
SUBCNT TYPE I,
LEVEL TYPE I,
LVL1 LIKE W_LVL1,
WERKS LIKE MAST-WERKS,
POSNR LIKE STPO-POSNR,
IDNRK LIKE STPO-IDNRK,
SBASE TYPE P,
AUSSS LIKE MARC-AUSSS,
MENGE TYPE P DECIMALS 5,
MEINS LIKE STPO-MEINS,
STD TYPE P DECIMALS 5,
MAV TYPE P DECIMALS 5,
VPRSV LIKE MBEW-VPRSV,
VORNR LIKE PLPO-VORNR,
ARBPL LIKE CRHD-ARBPL,
BMSCH LIKE PLPO-BMSCH,
UCOST TYPE P DECIMALS 5,
WLAR LIKE PLPO-LAR01,
WDL TYPE P DECIMALS 5,
WDLR TYPE P DECIMALS 2,
WDLH TYPE P DECIMALS 3,
WMSU TYPE P DECIMALS 5,
WMSUR TYPE P DECIMALS 2,
WMSUH TYPE P DECIMALS 3,
WTS TYPE P DECIMALS 5,
WTSR TYPE P DECIMALS 2,
WTSH TYPE P DECIMALS 3,
WAST TYPE P DECIMALS 5,
WASTR TYPE P DECIMALS 2,
WASTH TYPE P DECIMALS 3,
WOTHA LIKE PLPO-LAR01,
WOTH TYPE P DECIMALS 5,
WOTHR TYPE P DECIMALS 2,
WOTHH TYPE P DECIMALS 3,
OHCOST TYPE P DECIMALS 5,
MCOST TYPE P DECIMALS 5,
LIFNR LIKE EINA-LIFNR,
EXCOST TYPE P DECIMALS 5,
NETPR LIKE EINE-NETPR,
PEINH LIKE EINE-PEINH,
WCONV LIKE WCONV,
END OF ITAB2.

DATA: WPERIOD LIKE T009B-POPER,
WGJAHR LIKE CSSL-GJAHR.

CALL FUNCTION 'DATE_TO_PERIOD_CONVERT'
EXPORTING
I_DATE = SY-DATUM
* I_MONMIT = 00
I_PERIV = 'K4'
IMPORTING
E_BUPER = WPERIOD
E_GJAHR = WGJAHR
EXCEPTIONS
INPUT_FALSE = 1
T009_NOTFOUND = 2
T009B_NOTFOUND = 3
OTHERS = 4.

IF S_BASE EQ 0.
S_BASE = 1.
ENDIF.

FORMAT INTENSIFIED OFF.
** append multi level bom
SELECT * FROM MAST WHERE WERKS IN S_WERKS AND
MATNR IN S_MATNR.
SELECT SINGLE * FROM MARA WHERE MATNR = MAST-MATNR AND
MTART IN S_MTART.
IF SY-SUBRC NE 0.
CONTINUE.
ENDIF.
IF MARA-LVORM <> 'X'.
PARENT-MATNR = MAST-MATNR.
CHILD-MATNR = MAST-MATNR.
CHILD-WERKS = MAST-WERKS.
CHILD-STLAL = MAST-STLAL.
CLEAR ITAB.
CLEAR ITAB-LEVEL.
MOVE MAST-WERKS TO ITAB-WERKS.
MOVE MAST-MATNR TO ITAB-IDNRK.
MOVE MARA-MEINS TO ITAB-MEINS.
WCNT = WCNT + 1.
MOVE WCNT TO ITAB-CNT.
APPEND ITAB.
W_LEVEL = 1.
PERFORM GETCHILD.
ENDIF.
ENDSELECT.

SORT ITAB BY LEVEL DESCENDING.
LOOP AT ITAB.
CLEAR: ITAB1, ITAB2.
CLEAR: MARC-SOBSL, MARC-BESKZ, MARC-AUSSS.
SELECT SINGLE * FROM MARC WHERE MATNR = ITAB-IDNRK AND
WERKS = ITAB-WERKS.
IF SY-SUBRC EQ 0 AND
MARC-AUSSS NE 0.
S_BASE = XBASE + ( ( XBASE * MARC-AUSSS ) / 100 ).
ELSE.
S_BASE = XBASE.
ENDIF.
CLEAR: WOHCOST, WMCOST, WEXCOST, WUCOST.
PERFORM GET_ROUTE.
PERFORM GET_SUBC.
WTCOST = WOHCOST + WEXCOST.
PERFORM GET_BOM.
MOVE ITAB-WERKS TO ITAB1-WERKS.
MOVE ITAB-IDNRK TO ITAB1-IDNRK.
MOVE WUCOST TO ITAB1-UCOST.
APPEND ITAB1.
CLEAR ITAB2.
MOVE-CORRESPONDING ITAB TO ITAB2.
ITAB2-AUSSS = MARC-AUSSS.
ITAB2-SBASE = S_BASE.
MOVE WMCOST TO ITAB2-MCOST.
MOVE WOHCOST TO ITAB2-OHCOST.
MOVE WEXCOST TO ITAB2-EXCOST.
MOVE ITAB1-UCOST TO ITAB2-UCOST.
APPEND ITAB2.
ENDLOOP.

*loop at itab1.
* write:/ itab1-idnrk, itab1-ucost.
*endloop.
SORT ITAB2 BY CNT VORNR.
LOOP AT ITAB2.
WTCOST = ITAB2-MCOST + ITAB2-OHCOST + ITAB2-EXCOST.
IF ITAB2-LEVEL = 0 AND
ITAB2-SUBCNT = 0.
NEW-PAGE.
FORMAT COLOR COL_GROUP INVERSE ON.
CLEAR: MAKT-MAKTX, W_STD, W_MAV.
SELECT SINGLE * FROM MAKT WHERE MATNR = ITAB2-IDNRK AND
SPRAS = 'E'.
SELECT SINGLE * FROM MBEW WHERE MATNR = ITAB2-IDNRK AND
BWKEY = ITAB2-WERKS.
W_MAKTX = MAKT-MAKTX.
IF SY-SUBRC EQ 0.
W_STD = MBEW-STPRS / MBEW-PEINH.
W_MAV = MBEW-VERPR / MBEW-PEINH.
ENDIF.
WRITE:/ '***',
008 ITAB2-IDNRK,
034 MAKT-MAKTX,
076(6) ITAB2-AUSSS NO-ZERO,
096 ITAB2-MEINS,
101(12) ITAB2-UCOST,
114(12) W_STD,
127(12) W_MAV,
140(12) ITAB2-MCOST DECIMALS 3 NO-ZERO,
153(12) ITAB2-OHCOST DECIMALS 3 NO-ZERO,
166(12) ITAB2-EXCOST DECIMALS 3 NO-ZERO,
179(12) WTCOST DECIMALS 3 NO-ZERO.
FORMAT COLOR OFF INVERSE OFF.
ELSEIF ITAB2-LIFNR NE ''.
WRITE: /008 '**', 'Subcontact Cost'.
WRITE: /014 '*', ITAB2-LIFNR,
034 ITAB2-NETPR, '/' , ITAB2-PEINH.

ELSEIF ITAB2-VORNR NE ''.
WOHCOST = ITAB2-WDL + ITAB2-WMSU + ITAB2-WAST
+ ITAB2-WTS + ITAB2-WOTH.
IF WOHCOST NE 0.
CLEAR WVGW.
IF ITAB2-SUBCNT = '1'.
WRITE:/008 '**', 'Process Cost'.
ENDIF.
WVGW = ( ITAB2-WDLH / ITAB2-BMSCH ) * ITAB2-SBASE.
WRITE:/014 ITAB2-VORNR, ITAB2-ARBPL,
034 'DL',
040(10) ITAB2-WDLH,
052(10) ITAB2-WDLR,
064(12) WVGW,
078(16) ITAB2-WDL,
096 ITAB2-BMSCH LEFT-JUSTIFIED.
IF ITAB2-WMSUH NE 0.
WVGW = ( ITAB2-WMSUH / ITAB2-BMSCH ) * ITAB2-SBASE.
WRITE:/034 'MSU',
040(10) ITAB2-WMSUH,
052(10) ITAB2-WMSUR,
064(12) WVGW,
078(16) ITAB2-WMSU.
ENDIF.
IF ITAB2-WTSH NE 0.
WRITE:/034 'TOOLST',
040(10) ITAB2-WTSH,
052(10) ITAB2-WTSR,
064(12) ITAB2-WTSH,
078(16) ITAB2-WTS.
ENDIF.
IF ITAB2-WASTH NE 0.
WRITE:/034 'AST',
040(10) ITAB2-WASTH,
052(10) ITAB2-WASTR,
064(12) ITAB2-WASTH,
078(16) ITAB2-WAST.
ENDIF.
ENDIF.
IF ITAB2-WOTHH NE 0.
WVGW = ( ITAB2-WOTHH / ITAB2-BMSCH ) * S_BASE.
WRITE:/034 ITAB2-WOTHA,
040(8) ITAB2-WOTHH,
050(10) ITAB2-WOTHR,
062(8) WVGW,
072(10) ITAB2-WOTH.
ENDIF.
ELSE.
SKIP.
CLEAR: MAKT-MAKTX, W_STD, W_MAV.
SELECT SINGLE * FROM MAKT WHERE MATNR = ITAB2-IDNRK AND
SPRAS = 'E'.
SELECT SINGLE * FROM MBEW WHERE MATNR = ITAB2-IDNRK AND
BWKEY = ITAB2-WERKS.
IF SY-SUBRC EQ 0.
W_STD = MBEW-STPRS / MBEW-PEINH.
W_MAV = MBEW-VERPR / MBEW-PEINH.
ENDIF.
FORMAT INTENSIFIED ON.
WRITE:/001 ITAB2-LVL1,
008 ITAB2-POSNR,
014 ITAB2-IDNRK,
034 MAKT-MAKTX,
076(6) ITAB2-AUSSS NO-ZERO,
084(10) ITAB2-MENGE,
096 ITAB2-MEINS,
101(12) ITAB2-UCOST,
114(12) W_STD,
127(12) W_MAV,
140(12) ITAB2-MCOST DECIMALS 3 NO-ZERO,
153(12) ITAB2-OHCOST DECIMALS 3 NO-ZERO,
166(12) ITAB2-EXCOST DECIMALS 3 NO-ZERO,
179(12) WTCOST DECIMALS 3 NO-ZERO.
FORMAT INTENSIFIED OFF.
ENDIF.
ENDLOOP.

** get child parts
FORM GETCHILD.
SELECT * FROM STPO WHERE STLNR = MAST-STLNR
ORDER BY POSNR.
SELECT SINGLE * FROM STKO WHERE STLNR = STPO-STLNR
AND STLAL = MAST-STLAL.
SELECT SINGLE * FROM STAS WHERE STLNR = STPO-STLNR AND
STLKN = STPO-STLKN AND
STLAL = MAST-STLAL.
IF SY-SUBRC EQ 0.
CLEAR: W_DOT, W_LVL, W_LVL1.
PERFORM MOV_DATA.
CHILD-MATNR = STPO-IDNRK.
W_LEVEL = W_LEVEL + 1.
PERFORM SUBCHILD.
W_LEVEL = W_LEVEL - 1.
ENDIF.
ENDSELECT.
ENDFORM.

** get grand children parts
FORM SUBCHILD.
SELECT SINGLE * FROM MAST WHERE MATNR = CHILD-MATNR
AND WERKS = CHILD-WERKS.
IF SY-SUBRC NE 0.
EXIT.
ENDIF.
SELECT * FROM STPO WHERE STLNR = MAST-STLNR
ORDER BY POSNR.
SELECT SINGLE * FROM STKO WHERE STLNR = STPO-STLNR AND
STLAL = MAST-STLAL.
SELECT SINGLE * FROM STAS WHERE STLNR = STPO-STLNR AND
STLKN = STPO-STLKN AND
STLAL = STKO-STLAL.
IF SY-SUBRC EQ 0.
W_DOT = '.'.
PERFORM MOV_DATA.
CHILD-MATNR = STPO-IDNRK.
W_LEVEL = W_LEVEL + 1.
PERFORM SUBCHILD.
W_LEVEL = W_LEVEL - 1.
SHIFT W_LVL.
ENDIF.
ENDSELECT.
ENDFORM.

TOP-OF-PAGE.
WRITE:/ SY-DATUM,SY-UZEIT,
90 'ABC PRIVATE LIMITED',
180 'Page', SY-PAGNO.
WRITE: / SY-REPID,
88 'Roll-Up Cost (Multi-Level)',
180 SY-UNAME.
SKIP.
CLEAR W_LFLAG.
WRITE:/ 'Material No.:', ITAB2-IDNRK, W_MAKTX,
75 'Plant :', ITAB2-WERKS,
97 'Base Qty :', XBASE LEFT-JUSTIFIED.
SKIP.
ULINE.
FORMAT COLOR COL_HEADING.
WRITE: /001 'Level',
008 'Item',
014 'Component',
034 'Description',
075 'Scrap %',
084 ' Per',
096 'UOM',
101 'Roll-Up Cst',
114 'MM Std Cost',
127 'MM Mvg Cost',
140 ' Matl Cost',
153 'Process Cst',
166 'Sub-Con Cst',
179 ' Total Cost',
190 ' '.
WRITE: /034 'Act',
040 ' Std Val',
052 ' Act Rate',
064 ' Hours',
078 ' Cost',
096 'Base Qty',
190 ' '.
FORMAT COLOR OFF.
ULINE.

FORM MOV_DATA.
W_LVL2 = W_LEVEL.
CONCATENATE W_DOT W_LVL INTO W_LVL.
CONCATENATE W_LVL W_LVL2 INTO W_LVL1.
MOVE W_LVL1 TO ITAB-LVL1.
MOVE W_LEVEL TO ITAB-LEVEL.
MOVE MAST-WERKS TO ITAB-WERKS.
MOVE STPO-POSNR TO ITAB-POSNR.
MOVE STPO-IDNRK TO ITAB-IDNRK.
MOVE STPO-MEINS TO ITAB-MEINS.
ITAB-MENGE = ( STPO-MENGE / STKO-BMENG ).
WCNT = WCNT + 1.
ITAB-CNT = WCNT.
APPEND ITAB.
ENDFORM.

FORM GET_BOM.
CLEAR: WMCOST.
SELECT SINGLE * FROM MAST WHERE MATNR EQ ITAB-IDNRK AND
WERKS = ITAB-WERKS.
IF SY-SUBRC EQ 0.
SELECT * FROM STPO WHERE STLTY = 'M' AND
STLNR = MAST-STLNR AND
DATUV LE SY-DATUM.
SELECT SINGLE * FROM STKO WHERE STLTY = 'M' AND
STLNR = STPO-STLNR AND
STLAL = MAST-STLAL.
SELECT SINGLE * FROM STAS WHERE STLNR = STPO-STLNR AND
STLKN = STPO-STLKN AND
STLAL = STKO-STLAL.
IF SY-SUBRC EQ 0.
READ TABLE ITAB1 WITH KEY IDNRK = STPO-IDNRK
WERKS = ITAB-WERKS.
IF SY-SUBRC EQ 0.
WMCOST = WMCOST + ( ( STPO-MENGE / STKO-BMENG ) * S_BASE
* ITAB1-UCOST ).
ENDIF.
ENDIF.
ENDSELECT.
WUCOST = ( WTCOST + WMCOST ) / XBASE.
ELSE.
IF WTCOST EQ 0.
SELECT SINGLE * FROM MBEW WHERE BWKEY = ITAB-WERKS AND
MATNR = ITAB-IDNRK.
IF SY-SUBRC EQ 0.
IF MBEW-VPRSV = 'S'.
WUCOST = ( MBEW-STPRS / MBEW-PEINH ).
ELSE.
WUCOST = ( MBEW-VERPR / MBEW-PEINH ).
ENDIF.
ENDIF.
ELSE.
WUCOST = WTCOST / XBASE.
ENDIF.
ENDIF.
ENDFORM.

FORM GET_ROUTE.
CLEAR: WOHCOST, WCNT.
SELECT SINGLE * FROM MAPL WHERE WERKS = ITAB-WERKS AND
MATNR = ITAB-IDNRK AND
LOEKZ NE 'X'.
IF SY-SUBRC EQ 0.
SELECT * FROM PLAS WHERE PLNNR = MAPL-PLNNR AND
PLNAL = MAPL-PLNAL AND
DATUV LE SY-DATUM AND
LOEKZ NE 'X'.
SELECT * FROM PLPO WHERE PLNNR = PLAS-PLNNR AND
PLNKN = PLAS-PLNKN.
SELECT SINGLE * FROM CRHD WHERE OBJID = PLPO-ARBID.
SELECT SINGLE * FROM CRCO WHERE OBJTY = 'A' AND
OBJID = PLPO-ARBID AND
BEGDA LE SY-DATUM AND
ENDDA GE SY-DATUM.
CLEAR ITAB2.
MOVE ITAB-CNT TO ITAB2-CNT.
MOVE ITAB-LEVEL TO ITAB2-LEVEL.
MOVE PLPO-VORNR TO ITAB2-VORNR.
MOVE CRHD-ARBPL TO ITAB2-ARBPL.
MOVE PLPO-BMSCH TO ITAB2-BMSCH.
ITAB2-AUSSS = MARC-AUSSS.
ITAB2-SBASE = S_BASE.
IF PLPO-LAR01 CO SPACE.
WLAR = 'DL'.
ELSE.
WLAR = PLPO-LAR01.
ENDIF.
WVGW = PLPO-VGW01.
WVGE = PLPO-VGE01.
PERFORM MLCOST.
IF PLPO-LAR02 CO SPACE.
WLAR = 'TOOLST'.
ELSE.
WLAR = PLPO-LAR02.
ENDIF.
WVGW = PLPO-VGW02.
WVGE = PLPO-VGE02.
PERFORM MLCOST.
IF PLPO-LAR03 CO SPACE.
WLAR = 'MSU'.
ELSE.
WLAR = PLPO-LAR03.
ENDIF.
WVGW = PLPO-VGW03.
WVGE = PLPO-VGE03.
PERFORM MLCOST.
IF PLPO-LAR04 CO SPACE.
WLAR = 'AST'.
ELSE.
WLAR = PLPO-LAR04.
ENDIF.
WVGW = PLPO-VGW04.
WVGE = PLPO-VGE04.
PERFORM MLCOST.
ITAB2-OHCOST = ITAB2-WDL + ITAB2-WMSU + ITAB2-WTS +
ITAB2-WAST + ITAB2-WOTH.
WOHCOST = WOHCOST + ITAB2-OHCOST.
WCNT = WCNT + 1.
ITAB2-SUBCNT = WCNT.
APPEND ITAB2.
ENDSELECT.
ENDSELECT.
ENDIF.
ENDFORM.

FORM MLCOST.
SELECT SINGLE * FROM CSSL WHERE KOKRS = CRCO-KOKRS AND
KOSTL = CRCO-KOSTL AND
GJAHR = WGJAHR AND
LSTAR = WLAR.
IF SY-SUBRC EQ 0.
SELECT * FROM COST WHERE OBJNR = CSSL-OBJNR AND
GJAHR = WGJAHR.
IF WVGE = 'MIN'.
WVGW = WVGW / 60.
ENDIF.
IF WLAR = 'AST'.
ITAB2-WASTH = WVGW.
ITAB2-WASTR = COST-TKG012.
ITAB2-WAST = WVGW * COST-TKG012.
ELSEIF WLAR = 'TOOLST'.
ITAB2-WTSH = WVGW.
ITAB2-WTSR = COST-TKG012.
ITAB2-WTS = WVGW * COST-TKG012.
ELSEIF WLAR = 'DL'.
ITAB2-WDLH = WVGW.
ITAB2-WDLR = COST-TKG012.
ITAB2-WDL = ( WVGW * COST-TKG012 * S_BASE ) / PLPO-BMSCH.
ELSEIF WLAR = 'MSU'.
ITAB2-WMSUH = WVGW.
ITAB2-WMSUR = COST-TKG012.
ITAB2-WMSU = ( WVGW * S_BASE * COST-TKG012 ) / PLPO-BMSCH.
ELSE.
ITAB2-WOTHA = WLAR.
ITAB2-WOTHH = WVGW.
ITAB2-WOTHR = COST-TKG012.
ITAB2-WOTH = ( WVGW * S_BASE * COST-TKG012 ) / PLPO-BMSCH.
ENDIF.
ENDSELECT.
ENDIF.
ENDFORM.

FORM GET_SUBC.
CLEAR ITAB2.
IF MARC-SOBSL = 30 AND
MARC-BESKZ = 'F'.
SELECT SINGLE * FROM EINA WHERE MATNR = ITAB-IDNRK AND
LOEKZ NE 'X'.
IF SY-SUBRC EQ 0.
SELECT SINGLE * FROM EINE WHERE INFNR = EINA-INFNR AND
WERKS = ITAB-WERKS AND
ESOKZ = '3'.
IF SY-SUBRC EQ 0.
WCONV = ( EINE-BPUMN / EINE-BPUMZ ) * EINE-PEINH.
IF EINA-UMREN NE EINA-UMREZ.
WCONV = WCONV / EINA-UMREN * EINA-UMREZ.
ENDIF.
ITAB2-EXCOST = ( EINE-NETPR / WCONV ) * S_BASE.
ITAB2-LIFNR = EINA-LIFNR.
ITAB2-NETPR = EINE-NETPR.
ITAB2-PEINH = EINE-PEINH.
MOVE ITAB-CNT TO ITAB2-CNT.
MOVE ITAB-LEVEL TO ITAB2-LEVEL.
MOVE '9999' TO ITAB2-VORNR.
ITAB2-SUBCNT = 1.
APPEND ITAB2.
WEXCOST = ITAB2-EXCOST.
ENDIF.
ENDIF.
ENDIF.
ENDFORM.

Determine whether Planned / Production Order are included in the sap capacity planning in PP

2007-11-30T10:38:00.002+05:30

During the sap capacity planning, you can choose whether planned or producton order are consider during capacity planning.

The transaction code used is OPA2 - Selection Profile Name SAPA010.

The Production Order controls whether the production order is included in the capacity planning. In OPU3 - Specify Scheduling Parameters, if you tick the Generate Capacity Requirements, all production order created with the Order Type will be included in capacity planning.

If the plan order didn't appear in some work center check :-

OPU5 - Scheduling Type - e.g. Backwards - Assign a approciate Scheduling Type
OPPQ - BOM/Routing Selection - e.g. BOM select.ID 01 Rtg select.ID 01

Difference Between Planned & Prod. Orders in PP

2007-11-30T10:38:00.001+05:30

When user should opt for planned order instead of production order? I have high level knowledge that planned order is meant for REP. industry. Any other major parameters to be consider for Discrete, as both allow material kitting & backflush based on order number?

Planned orders are results of running MRP. Shortages of materials that are set to internal procurement will create planned orders, which can be converted into production orders. Production orders are like "hard copies", they cannot be adjusted by MRP anymore. Well that's for a discrete environment, not sure about repetitive manufacturing.

One we firm the planned order changes will be not reflected in the subsequent MRP, correct. e.g. BOM change. New components will not be recommended for firm planned order.

I'm assuming when you ask about when to use planned vs production orders you are asking when to use Repetitive Mfg (with PE planned orders) vs Discrete Mfg (with production orders). We use both and while we're not perfect in our approach yet we are gaining a better appreciation for the two.

For repetitive, the planning is much simpler, you basically run MRP against your demand and you get planned orders. You can change and firm these manually or you can use time fence strategies, and you can have multiple operations running through multiple work centres. They are very simple to maintain and use. Repetitive is normally run against shorter lead time build, where we don't need a high level of control. If we have the option we go with Repetitive.

Where we want a better level of control we go with discrete. Planned (LA) orders are created from a run of MRP against your demand. These are converted to production orders, released, and processed. There is a lot more control (and work) with this order type than we see with Repetitive planned orders. We can link documents to the order, we can change the routing and the BOM on the order, and we have better visibility of the individual orders while they are in manufacturing. Costing is against the order as opposed to Repetitive where the costs (and variances) are seen against the cost collector. After everything is complete, you still have a record against the build. The order stays intact, though it may be complete and closed, you still the retain history.

Firmed Planned Orders, What is its use in Production? in PP

2007-11-30T10:37:00.002+05:30

What is firmed planned orders and what is its use in production?
Under what circumstances should it be use. Is it applicable to MPS item alone?

Firming is applicable to all types of planned orders and not only MPS items.

It is used when you don't want certain planned orders to change during subsequent MRP runs.

Say today you have created certain palnned orders.

In a normal scenario, when you do the MRP run again, the planned order may get changed if the requirements have changed.

However as a normal business practice, it is not desired to change the production plans everytime there is a change in the requirement...especially in the immediate future (maybe a week or so).

We set this as the planning time fence depending on the MRP type settimg in the material master, you may have firm orders.

Apart from MPS items, MRP will also generate firm planned orders for materials with MRP type P1 to P4.

In addition to the above, any planned order that is manually changed is also firmed.

Mass Delete Planned Order in PP

2007-11-30T10:37:00.001+05:30

Use the collective display of planned orders, transaction code MD16.
You can select the data by different options and choose which ones or all that you need to delete.
Click the Delete button to trash them.

This will delete planned orders without deleting the planned independent requirements and sales orders.

Production Operations Overlapping in PP

2007-11-30T10:36:00.002+05:30

Operations - Start Finish

Normal Operations 1 - 01.01.XXXX 02.01.XXXX
2 - 02.01.XXXX 03.01.XXXX

Continuous Flow 1 - 01.01.XXXX 02.01.XXXX
2 - 01.01.XXXX 02.01.XXXX

Continuous Flow Configuration in Routing - CA02

Double click on the Work Center
Scroll down and look for the Overlapping section
Click Continuous flow prod. - input a Min send-ahead quantity if you want.

CA03 - Display Routing in PP

2007-11-30T10:36:00.001+05:30

The standard values Based Quantity = (Direct labour hours + Setup tools + Machining times + Adjust/Service Tools)
e.g. Operation :- 100 = 1 + 1 + 1 + 1

This means that to produce 100 pieces, you need a total activities of 4 hrs.