Scen Overview en HR PP

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J64: ProductionPlanning andDiscreteManufacturingOverview

SAP AG


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SAP AG 2006, Discrete Manufacturing (J64)

Business View Production Planning and DiscreteManufacturing

Business Benefits CostingProduction

PlanningBusiness Benefits

Costing Run:

The purpose is to calculate pricesfor the selected materials which arethen updated in the material masterrecords as the standard price. Thestandard price is used to valuategoods movements within the

company. The price update involvestwo steps: marking the calculatedprice (that is, setting this as the

future price of the material) and thenreleasing it (making it the currentstandard price). Before you canmark the prices, you have to allow itfor the company.

Production Planning:

This scenario describes a typicalplanning process starting withrough-cut planning. The previousyear's sales figures can be used asa basis. Rough-cut planninginvolves long-term planning with a

time frame of approximately oneyear. The planning data istransferred from SOP to Demand

Management. DemandManagement generates primaryplanning requirements, which are aprerequisite for the subsequentmaterial requirements planning(MRP) run. The MRP run is short-term planning, with a maximum time

frame of four weeks. In MRP, theBOM for the material is exploded

and planning takes place right downto component level. As a result,planned orders are generated forthe material to be produced. Ifinsufficient warehouse stock isavailable, purchase requisitions forthe raw materials required arecreated.

Edit Costing Run

Creating PlannedIndependent

Requirements

Creating PlannedOrder in MRP

Converting a PlannedOrder to Production

Order

Update Prices

Creating Rough Cut

Plan


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PlanningBusiness Benefits

Entering Goods IssueforBOM Components

Entering GoodsReceipt for

Manufactured Goods

Creating OrderConfirmation

Comparing Plannedand Actual Costs

Releasing ProductionOrder

(Batch Determination)

Shop FloorControl:

When a planned order is convertedto a production order, the product,the order quantity and the basicorder date are adopted from theplanned order. The production orderis released and the BOM

components are also reserved forproduction. Automatic batchdetermination based on the

expiration date is performed duringproduction order release. Thegoods issues can be postedmanually before order processingand the goods receipts are postedmanually as well. To collect activitycosts, you create order

confirmations.Target costs for the order lot size

are calculated when the order iscreated (preliminary costing).During the production process,costs incurred during production areupdated to the order, which enablesyou to keep track of and comparetarget costs and actual costs at anytime (simultaneous costing).


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Planning

Calculating Work inProcess

Calculating Variances

Revaluation at ActualPrices

Calculating ActualOverhead

Cost Object Controlling:

Cost object controlling in discretemanufacturing is an area in costaccounting that assigns the costsincurred in the production of

company activities (such asinternally manufactured materials)to those activities. Product cost byorder enables you to analyze costsat the level of manufacturing orders,

process orders, and productionorders. In product cost by order, themanufacturing orders themselvesare the cost objects. Costs chargedto manufacturing orders are usually

analyzed and settled by lot. Thismeans that variances can only beanalyzed after the entire plannedproduction quantity has been putinto inventory. The settings inProduction Planning & Control (PP,PP-PI) are required to costmanufacturing orders as part ofproduction execution.

Business Benefits


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SOP Process Flow

SOP Process Flow

Create Sales Plan

Create Production Plan

Transfer Planning Values to

Demand Planning


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Convert

Planned Order

Dependent

Reqmts

Reservations

Warehouse

Material Reqmts

Planning

Materials Requirement Planning - MRP

Demand

Program

Planned Ind.

Requirements

Production

Order


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Work Center

Work Center 3220

Routings Costing Scheduling

& Capacity

1010,-

2150,-

3160,-

Default values

Routings

Costing Data Sched. Data

Capacity Data


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Routing Work Center / Operation

Routing Header

Operation 10:

Labeling and Packaging

Material Components

Work center

Control key

Standard values

Activity types

Description

....


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A single-level BOM representsthe relationship between

an assembly and its components

Bill of Material

C10150

Finished good

3

FERT

PD

C10150

Finished good

3

FERT

PD

C30380 (12 KG)

Semi-finished

good 34

HALB

PD

C30380 (12 KG)

Semi-finished

good 34

HALB

PD

C40660 (12 PC)

Raw material 11

ROH

PD

C40660 (12 PC)

Raw material 11

ROH

PD

C50210 (1 PC)

Packaging

material tray 1

VERP

PD

C50210 (1 PC)

Packaging

material tray 1

VERP

PD


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Individual ConversionIndividual Conversion

Planned

orders

Production

orders

Collective ConversionCollective Conversion

Planned Order Conversion

Production

orderPlanned

orders


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Specify order typeSpecify order type

Define order itemDefine order item

Copy routingCopy routing

Lead time schedulingLead time scheduling

Copy bill of materialCopy bill of material

Optional changesOptional changes

Save production orderSave production order

FridayJuly

23 1999

TuesdayDecember

14 1999

Requirements planningRequirements planningRequirements planningRequirements planningManuallyManuallyManuallyManually

Availability checkAvailability check

AutomaticallyAutomaticallyAutomaticallyAutomatically

Optional (Customizing)

Production Order Creation


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Order proposal

(planned order)

Order creation

Availability

check

Order release and

batch determination

for components

Order settlement

Confirmations

Order headerOrder header

Operations

Components

Costs 2050

100

Material withdrawal

Goods receipt

Production Order Processing

Production Order


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Material

Goods movementGoods movement

Material

document

Accountingdocument

Warehouse

OperationOperation

Mat. comp.Mat. comp.

Prod.Prod. orderorder

CostsCosts

All materials are batch controlledAll materials are batch controlled

Update of stock quantitiesUpdate of stock quantities

Update of stock valuesUpdate of stock values

Goods Movement


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Goods issueposting

Materialdocument

Acctg.document

Updating stock quantitiesUpdating stock quantities

Updating stock valuesUpdating stock values

Reducing reservationsReducing reservations

Calculating actual costs and upCalculating actual costs and up--

dating the orderdating the order

Goods Issue


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Costing variant

Display planned/actual costs

Cost elements Cost itemization Cost component split

Planned costsPlanned costs

Material costs

Costs for externalprocurement

Production costs

Material overheadcosts

Production overhead

costs

Costs for external

processing

Cost elementsCost elements:: PhasesPhases

Gen. operation values

Standard values

Control key costing

indicator

ResourcesResources

Formula key forcosting

Cost center

Activity type

Formula constants

Cost calculationlog

Ind. "Rel. to costing"

Price

MaterialMaterial componentscomponents

OrderOrdertypetype / Plant/ Plant

Production Order - Preliminary Costing


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Production order costProduction order cost

Overhead calculationsOverhead calculations

- Work center

- Standard value

- Quantities

- Cost center

- Activity types

- Formulas

- Activity types

Operation

Internal activities costsMaterial costs

Cost of Production Order

- Quantities

- Prices

Work center Cost centerMaterialcomponents

- Periods

Activity cost


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OrderStatus

Pre-Released or Released Partially Delivered Finally Delivered or Technically Completed

Variances

Delivery

Value

Actual Costs

WIP at

Actual Costs

=WIP at

Actual Costs

=

-Delivery

Value

=

-

WIP and Variance Calculation in Lot-Based Cost ObjectControlling

Actual Costs Actual Costs


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Material

600

Product cost planning

Lotsize 1 PCCOCO--PCPC

Production OrderMat. C10150

8001.200

4002.400

-2.000

400

MaterialProductionSurcharge

GR

Variances

Actual Cost

CO-

PC

Material MasterStandard Price = 2000

Target Version 0

Price 150

Qty 150

Structure 100

Scrap 0Lotsize 0

Production

1100

Surcharge

300

Warehouse Price difference

Financial Accounting

2000 400

SettlementFI

CO-

PA

Settlement of Order (Example)


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