Sample Questions on PP

1. Which is the highest organisational level in SAP

a) Plant b) Client c) Storage Location

Ans: b

2. For Material Master record PP Data which is the highest organisational level

a) Plant b) Client c) Storage Location

Ans: a

3. What is the difference between F1 Help & F4 Help.

a) F1 is for possible values and F4 is for application help
b) F1 is for Application Help and F4 is for Technical Help
c) F1 is for Field Help and F4 is for possible entries.
d) None of the above

Ans: c

4. Variant Configuration is typically used in

a) Make – to – stock Environment
b) Make – to – Order Environment
c) Spare parts Sale
d) Repetitive Manufacturing Environment

Ans: a

5. Configurable Material check for a material is set in _____________

a) Basic Data b) MRP View
c) Sales View d) Classification

Ans:

6. Basic Data screen contains general data such as

a) Material Number
b) Material description
c) Base unit of measure
d) Technical data

Ans: a, b, c

7. Functions of Classification are

a) To find an appropriate object
b) To find similar objects
c) To establish that no appropriate object exists.

Ans:

8. Entering “/o” in command field

a) Ends current transaction
b) Ends the current cession
c) Opens new cession
d) Opens new transaction

Ans:

9. For creating Material Master the following Transaction Code is used :

a) md01
b) mm01
c) me01
d) mc01

Ans: b

10. The unit in which the stock keeping is done in a company is called

a) Stock unit of measure
b) Base unit of measure
c) Unit of issue
d) Purchase unit of measure

Ans: b

11. Batch is

a) Same as material code
b) Partial quantity of material managed separately from other quantity of same material in stock
c) A non reproducible homogeneous unit with unique specifications
d) None of above
e) All of above

Ans: b

12. A _____________________________ is a complete, formally structured list of the components that make up a product or assembly.

Ans:

13. Component in the BOM are allocated to operation in

a) BOM
b) Material Master
c) Routing
d) Work Center

Ans: c

14. BOM contains the following

a) List of Components
b) Qty of Components
c) Operation to which components is attached.
d) Unit of Measure of components

Ans: a, b, d

15. BOMs are always created as

a) Single Level
b) Multi Level
c) Components
d) Along with routings

Ans: a

Routings for Configurable Materials

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

Maintaining Characteristics for Configuration

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).

CA03 - Display Routing

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.

Production Operations Overlapping

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.

Reporting: Characteristics and Values

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.

1. 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.

2. 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.

Production Planning PP Tutorials

PP Bills of Material Guide
PP - Capacity Planning
PP Component Short Description
PP PDC Interface
PP KANBAN
PP - PI-PCS Interface: Linking of Process Control
PP - Production Orders
PP - Work Centers
Product Catalog and Online Store on the Internet
Product Cost Controlling Information System
Product Cost Planning
Production lot planning / individual project planning
Production Planning and Control (PP)
Production Planning and Control (PP)
Production Planning and Control (PP)
Production Planning & Control Workflow Scenarios Production Planning - Process Industries (PP-PI) Production Resources/Tools (PRT)
Product Lifecycle Management (PLM)
Product Safety (EHS-SAF)
Product Structure Browser
Capacity Evaluation (PP-CRP-ALY)
Capacity Leveling (PP-CRP-LVL)
Capacity Leveling in PP-SOP and LO-LIS-PLN
Capacity Planning in Customer Service and Plant Maintenance
Capacity Planning in Long-term Planning
Capacity Planning in MPS and MRP
Capacity Planning in Process Industries
Capacity Planning in Repetitive Manufacturing
Capacity Planning in Sales and Distribution
Capacity Planning in Shop Floor Control (PP-SFC)
Capacity Planning in the Project System
Material Requirements Planning
Capacity Planning in Shop Floor Control

Process Overview

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.

Process: Sales Order

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

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 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

1. Create a sales order and enter the configurable material as an order item.
2. 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.

3. 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.
4. 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).

See also:

Possible Combinations of Configuration Profiles

Process: Order BOM

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

1. Create a sales order and enter the configurable material as an order item.
2. 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.

3. 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.

1. Create a sales order and enter the configurable material as an order item.
2. 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.
3. 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.

4. 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.

SAP Production Planning Table

Demand Management
PBED Independent Requirements Data
PBIM Independent Requirements by Material

Repetitive Manufacturing
SAFK RS Header Master Data
S025 LIS -- Run Schedule Quantities
S026 LIS -- Material Usage
S028 LIS -- Reporting Point Statistics
CEZP Reporting Point Document Logs
CPZP Reporting Points - Periodic Totals

MRP Records
MDKP MRP Document Header Data
MDTB MRP Table Structure (no data)
PLSC Planning Scenario (Long-term Planning)
MDFD MRP Firming Dates
MDVM Planning File Entries
S094 LIS -- Stock/Requirements Analysis

Reservations
RESB Reservations/Dependent Requirements

Planned Orders
PLAF Planned Orders

Discrete Production
AFKO Order Header
AFPO Order Item Detail
AFVC Order Operations Detail
AFFL Order Sequence Details
AFFH Order PRT Assignment
AFBP Order Batch Print Requests
AFRU Order Completion Confirmations
AFFW Confirmations -- Goods Movements with Errors
AFRC Confirmations -- Incorrect Cost Calculations
AFRD Confirmations -- Defaults for Collective Confirmation
AFRH Confirmations -- Header Info for Confirmation Pool
AFRV Confirmation Pool
AFWI Confirmations -- Subsequently Posted Goods Movements

Classification
KLAH Class Detail
CABN Characteristic Detail
AUSP Characteristic Values
CAWN Characteristic Values
CAWNT Characteristic Value Texts
KSML Characteristic Allocation to Class
KSSK Material Allocation to Class

SAP PP Master Data Tables

MASTER DATA

Engineering Change Management
AENR Customer and priority
AEOI Revision Numbers

Work Center
CRHD Workcenter Header Data
CRCA Workcenter Capacity Allocation
CRCO Workcenter Cost Center Assignment
CRHH Hierarchy Header
CRHS Hierarchy Structure
CRTX Workcenter Text
KAKO Capacity Header
KAZY Intervals of Capacity

Routing
PLPO Routing Operation Details
PLKO Routing Header Details
MAPL Routing Link to Material
PLAB Relationships - Standard Network
PLAS Task List - Selection of Operations
PLMZ Component Allocation
PLPH CAPP Sub-operations
PLFH PRT Allocation
PLWP Maintenance Package Allocation
PLMK Inspection Characteristics

Bill of Material
STPO BOM Item Details
STPU BOM Sub Items (designators)
STKO BOM Header Details
MAST BOM Group to Material
STZU BOM History Records
STAS BOM Item Selection
STPF BOM Explosion Structure

Line Design
LDLH Line Hierarchy Header
LDLP Line Hierarchy Items
LDLT Line Hierarchy Takt Times
LDLBC Takts/No. Individual Capacities per Line
LDLBH Line Balance Header
LDLBP Line Balance Items
LDLBT Line Hierarchy Entry and Exit Takts

PRT's
CRFH PRT Master Data
CRVD_A Link of PRT to Document
CRVD_B Link of Document to PRT
CRVE_A Assignment of PRT data to Equipment
CRVE_B Assignment of equipment to PRT data
CRVM_A Link of PRT data to Material
CRVM_B Link of Material to PRT data
CRVS_A Link of PRT Internal number to PRT External number
CRVS_B Link of PRT External number to PRT Internal number

Table of the Order Production Operation

Which is the table of the order production operation details? I need to get the activities for production order :
Setup, Labor, Machine, Confirmed and to confirm.
I can see look at this in CO02 / Operation Overview (f5) / Operation Detalis / Qty-Activities

That is probably the hardest information to piece together, I used 5 tables with multiple joins to get User Fields for operations in a production order. Maybe you can use something simular.

AFKO - this is for your basic production header info - order number, basic finish date etc

S022 - this is for your operation header details - operation number, Work centre etc if you are only after the header details such as setup time and execution time, you can probably stop here without going to AFVC or AUFV (you definitely need AUFK if you want order status)

AUFK - this is for your order master data - Order released flag, order complete flag, technically complete date, you'll need this to filter out closed orders

AFVC - this is to link to the detail table - however I used the control key field in it so I would know whether it was a MILE stone or GPP1 for confirmation's sake

AUFV - this is the user field table - you may want to replace this with whatever detail you are after

Delete all the automatic joins:

AFKO -> AUFK on:
AUFNR -> AUFNR

AFKO -> S022 on:
AUFNR -> AUFNR
PLNBEZ -> MATNR

AFKO -> AFVC on:
AUFPL -> AUFPL

S022 -> AFVC on:
WERKS -> WERKS
PLNFL -> PLNFL
VORNR -> VORNR

The join below is for user fields in operation detail, you will have to find your own relevant table, but I assume the two key fields will be the same??

AFVC -> AFVU on:
AUFPL -> AUFPL - Routing number of operations in the order APLZL -> APLZL - General Counter for order

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In PP,Mass Delete Planned Order

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.

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

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.

In PP,Difference Between Planned & Prod. Orders

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.

In PP,BOM components never explode

4.6x

After executing MD02, you found that the components did not explode accordingly:

Checklist for checking :-

Material Type must be FERT - Finished products or HALB - Semi-finished products

MM02 - MRP View 2 - Procurement type ( X - Both procurement type or E - In-house production)

CS02 - Validity periods of Parents parts and Components

In PP,BOM Display Changes

Transaction CS80 keep track of changes done to the BOM. To check all the changes, at the second screen, you must specify the earliest possible Selection date. If don't know the earliest date, just key in XX.XX.1990. Click Goto for the various type of changes to be displayed.

CC04 - Product Structure Browser.
This is a great transaction for viewing and modifying anything that were related to the Material. e.g BOM, Routing etc.

CS20 - Mass changes : Material Selection - You add or delete a component from all the BOM.

In PP,Configure Phantom assembly

This indicator determines the special procurement type of a material which is either procured externally or produced in-house.

The system determines the special procurement key from the Procurement type and Special procurement fields in the material master record (Detail Screen: MRP 1) and displays the value if the BOM is only allocated to one plant. Only the values which are relevant to the explosion type are displayed for a BOM item.

This type of assembly is only required for engineering purposes, but it does not occur physically in the course of production. In the planning run, dependent requirements are not created for the header material of the assembly but are transferred immediately to the component materials. In the standard SAP System, the special procurement key phantom assembly has the value 50.

BOM
Design Production
0 Z Z

1 B C B C

2 B1 B2 B1 B2

B - In production, to produce Z, you need B1, B2 and C. You need not produced B as it is a phantom assembly. e.g. mirror-image parts, the left and right car doors.

In PP,The Concept (use) of Phantom Assembly

A classic example of phantom assembly is packing material, they cannot be included in the BOM of the FG but still it is an assembly that goes with the FG.

Phantom assembly is something that you produce/used but you cannot count/measure for it, you only can measure for its component. For example, you are the producer of clip (paper clip) you cannot measure how much paper clip you already produce, all you know is how much wire I used to produce clip and how much box of clip, I have produce if you want to maintain material master for the Clip before it goes to the box, you can assume that the clip is phantom

A phantom assembly is used when you want to be able to structure a BOM so it is easy to understand, but don't want to create too many production orders. Assume an auto Engine. There are hundreds of components. You might structure them as: Engine block and parts, camshaft and parts, and 6 piston assemblies. But you don't want to create 3 production orders, too much hassle. So you want to issue the components for the piston assembly in the same production order as the Engine block. So you create a new material number for the Piston assembly, but you mark it as a phantom assembly. That means that when you create the bom for the Engine assembly, you only have two assemblies, the Engine block and the Camshaft. You add the phantom assembly for the Piston Assembly to the Engine block BOM, saying it requires 8 of the phantom assembly. When the production order is created for the Engine block, the picklist will also include all of the components of the 8 piston assemblies.

1) When to use, or not use a phantom assembly?
If you need to do cost accounting on how many hours it takes to assemble a piston assembly, it cannot be a phantom assembly, because as a part of the Engine block assembly, the labor costs are included in the Engine block production order, and therefore in the standard cost.

2) Can the assembly people pick out the parts for the phantom assembly from the all of the components in the Kit?
If the guy assembling the Engine Block gets confused because of all of the components for the Piston assemblies are there, then it cannot be a phantom assembly. But if they can seperate them easily, go for it. A printed circuit board assembly should never be a phantom assembly, because all of those little parts for each type of PC board must be kept separate.

3) Do you usually build 100 piston assemblies, put them into stock, then issue 8 at a time to build an Engine Assembly?
If so, it is not a phantom assembly. If the Piston assembly is a phantom, you only build the 8 you need while you are building the Engine Block assembly. You normally do NOT store a piston assembly (phantom assembly) in stock.

4) However, sometimes a customer calls and wants you to send them all of the components for One Piston Assembly.
By having it set as a phantom assembly, even though you don't usually create seperate production orders, in this case you CAN create a production order for one, pull the components, close the PO, and send the parts off to your customer.

5) You complete a Engine Assembly.
As you are walking it back to the stockroom, you drop it on the floor, and it breaks! Damn, but you can still save the piston assemblies. Since they do have a SAP material number, you CAN put those back into stock. Most MRP systems WILL recognize that you happen to have 8 piston assemblies in stock, and will issue those whole assemblies to the next order for a Engine Block.

In summary:
1. When to use phantom assembly:
a. You want costing to be done but will not treat that stage as confirmation point.
b. You find that operation is not so important i.e you do not want analyse the work center output details, etc.
c. You want the operation to be in the BOM as well as routing, so that product go through that operation.

2. When not to use phantom assembly.
a. If you find that operation is critical - you cannot treat that as phantom.
b. If you are sending the product to outside for subcontracting operation.

In PP,Work Center Creation and Change

Work Center (CR01 - Create, CR02 - Change, CR03 - Display)

Using the data maintained for a work center, you can

• determine which machines or people are to be used in the operations
• calculate costs, capacities and dates for the operations

OP42 - Configure the default value for Work Center during the initial creation.

After creating many work center in the Routing, the users might want to check what materials and components allocation have been updated with this work center. You can used this program Work Center in Routing - Search through all the routing for the material and component allocation used.

The standard program transaction CA80, checks where the work center was used in the routing. However, it did not list the components allocation for the work center.

Pooled Capacity field - When a production order 1234567 has the capacity requirement on its work center Wxxxxx. It means it has the requirement on pooled capacity Pxxxxx. If more than one work center shared this pooled capacity, the requirement (transaction CM01) will be shown on all the work center with the SAME shared pooled capacity.

In PP,Configuring an Additional Activity Type

Additional Activities Type for Work Center

The following are the steps to configure an additional activities type:-

• OP51 - Check Settings for formulas
• OP54 - Check formulas for Costing
• Ensure that usage of the parameters are indicated. Some parameters are appropriate for capacity calculation but not for schedule calculation. If you like to find out the parameter id, you could use the Search Fld. for Param. pull down button to do so.
• KLH2 - Maintain hierarchy of Activity type group.
• OP19 - Define standard value key
• The purpose of standard value keys is to group together a set of parameters for the purpose of ensuring that the standard values for the parameters are supplied in the operations of the routing. This is so that the formula (for calculating cost, schedule, and capacity) could have the necessary figures to work with. Once the parameters are associated with the standard value keys, work centers quoting this standard values will be able to dictate whether or not the parameter values are optional or mandatory entry in the operations of the routing. The pre-requisite for using this transaction is that the parameters must have been pre-created.
• KA01 - Create Primary Cost Element for the new activities type.
• KL01 - Create Activity Type tied to the primary cost element. (the Cost element field)
• KP26 - Change Activity Type/Activity Price Planning - maintain the Variable price

If the user include the additional activities in their work center, the routing that used the work center will required more time to finished the jobs.

The operations Start and Finish date will be extended due to the extra time spent on the work center. The cost of production increases in line with the extra activity which will be reflected in the Factory Output when you do a cost analysis in the production order. The new activity will have a price attached to it and the moving average price will increase.

In PP,Total Plan Activities in Minutes

afru -> Order completion confirmations
afru-smeng -> Operations qty

afvv -> DB structure of the quantities/dates/values in the operation
afvv-bmsch -> Base quantity
afvv-vgw01 -> Standard value for Direct Labour
afvv-vgw02 -> Standard value for Setup
afvv-vgw03 -> Standard value for Machine Time
afvv-vgw04 -> Standard value for Adjustment of Tool

Formula
Direct Labour = ( afru-smeng / afvv-bmsch ) * afvv-vgw01 * 60.
Setup = afvv-vgw02 * 60.
Machine Time = ( afru-smeng / afvv-bmsch ) * afvv-vgw03 * 60.
Adjustment of Tool = afvv-vgw04 * 60.

Formula
CR03 - Display Work Center
At CR03, click Assignments. Then double click on the Cost Center.
Place your cursor at the Activity type, click Extra -> Formula -> Display.

In PP,To compare multiple BOMs

Used the BOM Comparison report (CS14). It will compare two Bill of materials for you.

Table for BOM fields

How to find Table in which the field 'Item ID' in the BOM (T-code cs01/cs02) is maintained? I had tried T-code SE16, but could not found tables for BOM. In technical help I could see that Field Name is 'IDENT' and Data Element is 'ITMID'.

<<<
The BOM tables are as follows:

MAST---->Material to BOM Link

STKO ---->BOM Header

STPO----->BOM item

Go and run this tables and you will get the desired detail

Pallab

<<<
I had already checked the following tables but could not find the desired result.

STKO ----BOM - header

STPO ----BOM - item

STAS ----BOMs - Item Selection

STPN ----BOMs - follow-up control

STPU ----BOM - sub-item

STZU ----Permanent BOM data

PLMZ ----Allocation of BOM - items to operations

MAST ----Material to BOM link

KDST ----Sales order to BOM link

Can somebody suggest something different. Most important thing is I could not find any tables linked to BOM in T-Code SE16.

Navin

<<<
The field you are looking for is, in the Table STPO, and field name ITMID, with data element CS_ITMID.

They both refer to the "External identification of an item", which is reserved for the "External system item number" for that BOM (just a guess). In case you are transferring your BOM from an external system.

For your information:
Why is it ITMID instead of IDENT?

That's because, system stores data in a database table, but during transactions it uses temporary data carriers (e.g. structures) until the program finishes. When the program is finished, it writes the temporary data to the actual database table. In your case, the database table is STPO, and the temporary data carrier is the RC29P structure. The field IDENT in RC29P is displayed during CS01/CS02, but when you save the BOM, it's written to the corresponding database table STPO's ITMID field.

If you enter a number in this field while you are creating an item in the BOM, it will be written to the field STPO-ITMID. However, if you don't enter a number yourself, system will fill that information itself, with a sequential number. But this time, system writes this number to the STPO-STVKN field. Therefore, system has 2 fields in the database table STPO for this data, but during the BOM editing, it displays only one of these fields. If data entered by user, it's displayed, if not, the system-given automatic number is displayed instead.

This information i didn't know before, but i knew before the use of temporary data during transactions. So, i checked the field during CS02, and i saw that field is RC29P-IDENT, and i guessed that it was stored in STPO table. Then i checked the RC29P-IDENT and i saw it was CHAR type with length 8. I looked for the fields in STPO with type CHAR and length 8, the rest was easy to find.

Osman Karslioglu

<<<
If you use the tcode:se11 , you will find out that , the field which you need is in the JHEAD. And the JHEAD is a structure.

Skywalker

<<<
Structure JHEAD and its IDENT field has no use with BOM data.

You can also test this information.
1. Create a BOM.
2. Enter a BOM item: item cat, material number, and quantity, and press enter. (you will see, system enters 00000001 into Item ID automatically)
3. Enter another BOM item: item category, material number, quantity, and Item ID (eg. enter "TEST"), and press enter. (you will see that your text is displayed in the Item ID).
4. Save your BOM.
5. Enter the BOM again with CS02 and display BOM header. note the BOM number (just below plant and material numbers) 6. Run SE16 and enter the BOM number you noted in step 5.
7. Check the fields STVKN and ITMID fields. You will see:

STVKN, ITMID
00000001, for the first BOM item.
00000002, "TEST" for the second BOM item.

But in transaction CS02, system displays the Item ID
00000001 for first BOM item, and "TEST" for second BOM item.

In PP,Long Term Planning BOM Selection

We do yearly budget with long term planning and we want to use it to transfer PP activity.

In order to do it we do the defination in as following:

1) define the routing selection for long term planning in planned order defination.
2) we define a BOM use costing usage.

After we run MRP in the long term planning screen.
Later we check the planned order and we find the routing selection is right but the bom selection is not right. It is didnot use the cost bom we defined.

Is it because the cost routing didnot related with production in the defination of bom usage defination?

The causes may be due to many factors...

Check:
1. Planning scenario for correct BOM application
2. Check spro for Alternative Determination(under BOM) and Selection ID
3. Order of priority of BOM usage

Define production version for a material with correct routing and BOM mentioned in it.
Attach this prod version to material in MRP3 view.

Also change the BOM selection in MRP3 view to 2 i.e. Selection by production version only.
Now if there are going to be multiple versions for the same material and in LTP you want that to be getting selected automatically, then you can use quota arrangement.

Thans for your answer. Yes we can use the solution to solve our problem. But we still have some problem:
1.We use the long term planning for budget use. You know when you do budget you could not finish in a short period and it means it should not effect the actual business. If you change quto when you want to swtich it takes time to do it.

2. You the routing if you use another group counter and when you get the cost run result you could not make analysis base on your solution.

We encountered teh same problem, so we took a copy of the actual production system towards a budget box; changed all BOM's and routing's for budgetting reasons, run LTP on this box; if ok copy the new BOM's and routings back to productive system.

In PP,Attach The Components Drawing In a BOM

What are the procedure to attach the components drawing in a BOM?

1) Attaching document as an item in the item overview:
…go to the `General Item Overview' screen
…select the tab page `Document'
…enter item category `D'
…dropdown and select the document you want to attach
…the system automatically selects the respective document type, document part, document version and document description

2) Attaching document to an item:
…go to the `General Item Overview' screen
…select the particular item by F2
…the item all data screen appears
…go to tab page `document assignment'
…dropdown and select the `document type' you want to attach …dropdown and select the document you want to attach
…the system automatically selects the respective document part, document version and document description

3) Attach document to the header material:
…go to header overview screen
…go to tab page `document assignment'
…dropdown and select the `document type' you want to attach
…the system automatically selects the respective, document part, document version and document description
(Transaction CV01N for document creation)

Interface Settings PP

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

PP Faqs -II

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 PP

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 PP

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 - III

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.

Routing - II PP

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 - I PP

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 PP

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 PP

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 - IV PP

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

M R P - III PP

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 - II PP

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 - I PP

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:

1. 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 .
2. Single Item / Multi Level from MPS - Transaction Code MD41 - All levels are planned - A , B & C
3. 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-IX PP

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

Production Orders-VIII PP

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--VII PP

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-VI PP

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-V PP

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-IV PP

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-II PP

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-III PP

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-I PP

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 PP

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.