Published on October 7, 2014
1. LO215 Production Orders LO215 Release 640 04/06/2006
2. LO215 Production Orders LO215 Production Orders SAP AG 1999 SAP AG System R/3 Release 4.6C October 2000 5004 2355
4. Group products and services are those that are set forth in the express warranty statements accompanying such products and services, if any. Nothing herein should be construed as constituting an additional warranty.
5. Production Planning Level 2 Level 3 LO050 5 days Manufacturing Planning & Execution for Discrete & Repetitive SAP AG 1999 LO980 3 days Engineering Change Management LO235 2 days KANBAN LO205 3 days LO985 3 days Classification LO955 3 days Batch Management LO230 5 days LO720 2 days CAP Calculation of Standard Values LO275 2 days Special Features of LIS in Production LO935 2 days Logistics Info Planning LO210 5 days Production Planning LO215 5 days LO225 3 days Repetitive Manufacturing Capacity Planning LO930 2 days Logistics Information System (LIS) Reporting LO206 3 days Basic Data Part 2 Basic Data for Discrete Manufacturing Production Orders LO990 5 days Variant Configuration Part 1 LO991 3 days Variant Configuration Part 2
6. Requirements Necessary: Knowledge of Production Planning and SAP AG 1999 Control LO205 Basic Data for Discrete Manufacturing LO206 Basic Data Part 2 Recommended: LO050 Manufacturing Planning and Execution for Discrete and Repetitive
7. Target Group Members of the project team who are responsible for the implementation of production orders (consultants and administrators) Managers and employees in production areas (production schedulers, controllers, supervisors and operators) Duration: 5 days SAP AG 1999 Information for participants The training materials are not designed to be a self-teach program. They are only complete when used in conjunction with the explanations of the instructor. You are given space on each page of the training materials to write down this additional information.
8. Course Overview: Contents Course Goals Course Objectives Course Content Course Overview Diagram Main Business Scenario SAP AG 1999 (C) SAP AG LO215 1-1
9. Course Goal SAP AG 1999 At the conclusion of this course, you will be able to: Use production orders. Create, release and fully implement production orders. You will be able to make system settings and also understand production orders in context. (C) SAP AG LO215 1-2
10. Course Objective(s) SAP AG 1999 At the conclusion of this course, you will be able to: Classify production orders in the production planning and execution environment (demand management, requirements and materials planning, sales order processing and so on) Implement or apply production orders and their most important functions Understand and use the basic order management functions in detail Use the information systems for production orders Take into consideration the integration relationships within the production order Teach yourself additional special functions (C) SAP AG LO215 1-3
11. Course Content Preface Unit 1 Introduction Unit 2 Overview Unit 3 Order Structure / Processing Unit 4 Order Creation / Order Change Unit 5 Order Release Unit 6 Printing Order Documents Unit 7 Material Staging Appendix SAP AG 1999 Unit 8 Order Control Unit 9 Confirmations Unit 10 Goods Receipt Unit 11 Settlement, Archiving and Deletion Unit 12 Information Systems Unit 13 Mass Processing and Automation Unit 14 Collective Orders (C) SAP AG LO215 1-4
12. Course Overview Diagram (1) 1 Introduction Overview 2 Order Structure / Processing 3 Order Creation / Order Change 4 Order Release 5 Printing Order Documents 6 Material Staging 7 SAP AG 1999 Order Control 8 Confirmations 9 Goods Receipt 10 Settlement, Archiving and Deletion 11 Information Systems 12 Mass Processing and Automation 13 Collective Orders 14 (C) SAP AG LO215 1-5
13. Course Overview: Main Business Scenario SAP AG 1999 Your company manufactures order-related products. You belong to the team in your organization that implements the part of production planning and control dealing with R/3 production orders. This means implementing the whole process chain for in-house production, which will allow your company to organize, steer and execute plant production using the R/3 System. Important stages of order-related manufacturing are creation, release, machine usage, printing of papers, material withdrawal, execution, confirmation, goods receipt and settlement. In practice, these functions are integrated into other areas in your company (controlling, material management and so on). It is therefore necessary to consider the extensive integration relationships during implementation. (C) SAP AG LO215 1-6
14. Overview: Contents Overview of the process chain for order-related production The process chain in other production planning and control scenarios Characteristics of order-related production Order-related production in the organization structures of the R/3 System Master data prerequisites for production orders SAP AG 1999 (C) SAP AG LO215 2-1
15. Overview: Topic Objectives SAP AG 1999 At the conclusion of this unit you will be able to: Recognize the different steps in the process chain for order-related production Recognize the most important characteristics of order-related production Define how production orders are classified in the R/3 application component PP and in the organization structures (C) SAP AG LO215 2-2
16. Overview Diagram (2) Introduction 1 2 Overview Order Structure / Processing 3 Order Creation / Order Change 4 Order Release 5 Printing Order Documents 6 Material Staging 7 SAP AG 1999 Order Control 8 Confirmations 9 Goods Receipt 10 Settlement, Archiving and Deletion 11 Information Systems 12 Mass Processing and Automation 13 Collective Orders 14 (C) SAP AG LO215 2-3
17. Production Orders in Practice "Special" engineer-to- "Special" engineer-to- order order production production SAP AG 1999 Make-to-order production Make-to-order production Production Production bbyy lloott ssiizzee P R O D U C T C O M P L E X I T Y Assembly production/ Assemb.-to-order prod. Period-oriented production/ flow manufacturing with takts Process manufacturing Mass production P R O D U C T S T A B I L I T Y You can apply the R/3 Production Planning System in a variety of production types. The production types used in practice are essentially dependent on product stability, product complexity and production processes. (C) SAP AG LO215 2-4
18. Subsystems of the PP Application SAP AG 1999 PP CRP Capacity Planning PP KAN KANBAN PP PP PC Prod. Costing PP IS Prod. Info System PP REM Rep. Mfg PP SFC Shop Flloorr Conttroll PP MRP Mat. Rqmts Planning PP SOP Sales & Oper. Planning PP PI Process Mfg PP MPS Demand Mgmt PP BD Basic Data The Production Planning (PP) application incorporates a number of integrated working subsystems. Each time you use the R/3 system, you should determine precisely which components are appropriate to your needs. PP-Shop Floor Control is the subsystem for order-related production. (C) SAP AG LO215 2-5
19. Order-Related Production: Characteristics (1) Order-related production Based on production orders with order category '10' Production by order lot sizes (see Lot-Sizing Procedure) Integrated logistical and controlling functionality Production by production versions (for example, production lines) Detailed status management Full integration into capacity planning PDC - Interface (PP-PDC) for download and upload Material staging controlled by material reservations SAP AG 1999 (C) SAP AG LO215 2-6
20. Order-Related Production: Characteristics (2) Availability checks for material, capacity, production resources and tools Various options for entering actual data (quantity, time) Order, operation, time event and progress confirmations Extensive order-related or product-related controlling Full integration in the Logistics Information System (LIS) and Business Information Warehouse (BW) Archiving and retrieval function Numerous special functions multi-level collective orders, trigger points, serial numbers, order split, external processing, rework, WIP, variance calculation, cross-plant production, batch creation and batch determination, co-products and so on SAP AG 1999 (C) SAP AG LO215 2-7
21. Cross-Application Functions Planning Demand program Sales reqmts Inventory Capacity planning SAP AG 1999 Material forecast Sales & Distribution B A C D E Costing Requirements planning Production order Order processing Goods receipt Order settlement Planned order Goods issue Purchase requisition Purchase order Goods receipt Invoice receipt Production order management is a central component of a complex process chain that starts with independent requirements (planned or customer requirements) and ends in the issue of a finished product. Production order management in the SAP System only controls the whole process of in-house production. Production order management uses the following system components: ALE, Workflow, Customizing, word processing, factory calendar, classification, communication and graphics. (C) SAP AG LO215 2-8
22. Production Planning and Control Data SAP AG 1999 Master data Factory calendar Mat. master Work centers Bills of material Routings Prod. resources/tools CAPP formulas Documents Transaction data Production orders Confirmations CO object (cost collector) Material movements (goods receipt / issue) Data that does not change frequently is defined as master data of the Production Planning System. Transaction data are documents that have a restricted time application. In the Production Planning System these are production orders. Documents for confirmations, costs (CO objects) and material movements are assigned to the production orders. (C) SAP AG LO215 2-9
23. Corporate Order Management Sales-Related Goods sold Goods in stock Company Internal Cannot be activated Can be activated Order Order Order Assignment to a sales order Customer Warehouse Cost center Asset portfolio Logistic functions (quantities and values) Cost accounting functions (values) Goods for the market Internal company goods and services SAP AG 1999 Order Assignment to a material Overhead cost orders Capital investment orders Corporate order management is divided into two basic forms: Sales-related orders and company internal orders. Within company internal orders, a distinction has to be made between: Orders purely for object control within cost accounting (for example, for promotional purposes or for use in trade fairs). Productive and value-added orders that can be activated (for example, for in-house production on a production line). In the R/3 System, both basic order forms are assigned to SAP applications via order category. Examples: Production order (PPS) -> PP Production Planning Plant maintenance order -> PM Plant Maintenance Network -> PS Project System Overhead cost order -> CO Controlling Capital investment order -> CO Controlling (C) SAP AG LO215 2-10
24. Document Type, Order Category, Order Type SAP AG 2003 Document type Orders Material accounting documents Financial accounting documents Order category PP production order PP process order PS network CO internal order CO production order CO model order PM plant maintenance order Order type Production order (internal number range) Production order (external number range) Production order (special types) The document type is used to differentiate between business transactions in the R/3 System. Orders are one category of business transaction. Orders are divided up according to order category, as it is possible to have different orders within the different applications. The system predefines fixed order categories for each application. You have the option of individually defining order categories for each order type within an application. An order type is used to control different processes: Number assignment Setting default values User-specified status management User-specific field control (not for production orders in Release 4.7) Control of special functions (activating BDE, QM, LIS,....) You define the settings for this in Customizing. (C) SAP AG LO215 2-11
25. Definitions in the Production Order What is being produced? When is it being produced? How much has to be produced? For whom are we producing? (cost object) Which resources and methods are being used in the production? Which costs are incurred by the production? SAP AG 1999 Products Activity Planned order dates Basic order dates Calculated dates Confirmed dates Release Start Final Planned order quantity Production order quantity Confirmed quantity Material Cost center Order Asset Material usage Prod. resources/tools Checks Planned Actual The production order is determined by a series of definitions for manufacturing a product. (C) SAP AG LO215 2-12
26. Production Orders and Organizational Structures Sales organizations Purchasing organizations Storage locations/batches/special stocks SAP AG 1999 Organizational units Demand management Requirements planning Shop floor control Production order Inventory management Company Controlling areas Company codes Valuation areas Plants Production orders generally relate to the organizational unit plant. The organizational units above a plant can be structured in various ways. (C) SAP AG LO215 2-13
27. Master Data for the Production Order Material BOM Work center Routing Prod. resources/tools SAP AG 1999 Procurement type E or X MRP, work schedule, acct. and costing data Material status (MARA and MARC) Material usage (Mat. no., item cat., quantity) Storage location (proposal for withdrawal) Operation default values Available capacity and formula requirements Activity type and formula costs Operations Standard values Required quantity and usage value Control data Required quantity and usage value Control data BOM Routing The material to be produced must have already been designated procurement type in house production (X,E). The material status must be released for production on both a cross-plant level (MARA) and a plant level (MARC). At least one plant specific view (MRP and/or work scheduling) as well as financial accounting and costing views must be maintained for the material. You prepare BOMs as single level BOMs. A special selection procedure chooses the correct BOM. After you have prepared a routing, a special selection procedure chooses the correct one. (C) SAP AG LO215 2-14
28. Order-Related Production - Roles Sales planning Sales planning Plant reqmts Production planner Production scheduler Design engineer SAP AG 1999 Production operator Production scheduler PPrroodduuccttiioonn Production preparation Production preparation Plant manager MRP controller Production operator Production scheduler (supervisor) Docu. & analysis Docu. & analysis Detailed Planning Industrial engineer Plant manager Quality inspector Within the development of the SAP product "mySAP.com", computer-supported work centers have been created along the entire process chain for order-related production. Production order management touches on at least those roles shown on the slide. Individual roles are assigned different activities (tasks), authorizations and responsibilities that correspond to the actual daily work carried out in practice. (C) SAP AG LO215 2-15
29. Production Order - Symbol Overview Order header Sequence overview Operation overview Component overview Document overview Trigger point overview Status overview Collective order overview Detail screen (operation, component, PRT, ...) Log Key SAP AG 2003 Change Display Save Deletion Schedule (order, collective order) Cost Check availability (material, capacity, PRT) Release (order, operation) Print Enter long text (text editor) Generate object (for example, order) Execute program (function) Update The slide shows the most frequently used pushbuttons (symbols) in the production order. The symbols have been arranged on the individual production order screens in such a way that you can always find the relevant symbol in the same place on the screen. Order functions are arranged on the left and navigation functions on the right. In the overviews of the operations, components and production resources/tools, the relevant pushbuttons for the individual object have been arranged underneath the overview. Where it was considered appropriate, pushbuttons were placed directly next to a data field. (C) SAP AG LO215 2-16
30. LO215 - Commonly Used Abbreviations • PP-SFC • Order type • Order type parameters • Scheduling parameters of the order type • Task menu (SAP) Transaction session_manager • Customizing Transaction SPRO SAP AG 1999 Production Planning - Shop Floor Control SAP + LO + PP + Shop Floor Control Table T003O SPRO + SFC + Master Data + Order Types Table T399X SPRO + SFC + Master Data + Order-Type Dependent Parameters Table TCX00_FA SPRO + SFC + Operations + Scheduling + Scheduling Parameters SAP + Tools + Accelerated SAP + Customizing + Edit Project During the LO215 course, the instructor may repeatedly use certain terms, tables and shortcuts. The slide contains the most important terms and their menu paths. The instructor will not always repeat these menu paths. (C) SAP AG LO215 2-17
31. Overview: Summary SAP AG 1999 You have gained an overview of the process chain for order-related production and the role it plays in the R/3 System. You have learned about the prerequisites for master data. You have been informed about the role of order management in the organization structures of the R/3 System. The orders are assigned to an application using the order category. This determines the scope of the functions. The order types serve as a control for special functions per order category. (C) SAP AG LO215 2-18
32. Order Structure and Processing: Contents Order data structure Production order screens Overview of order processing SAP AG 1999 (C) SAP AG LO215 3-1
33. Order Structure and Processing: Course Objectives SAP AG 1999 At the conclusion of this unit you will be able to: Describe production order data structure Describe the most important production order screens Summarize the main functions of order processing (C) SAP AG LO215 3-2
34. Introduction 1 Overview 2 3 Overview Diagram (3) Order Structure / Processing Order Creation / Order Change 4 Order Release 5 Printing Order Documents 6 Material Staging 7 SAP AG 1999 Order Control 8 Confirmations 9 Goods Receipt 10 Settlement, Archiving and Deletion 11 Information Systems 12 Mass Processing and Automation 13 Collective Orders 14 (C) SAP AG LO215 3-3
35. Elements of an Order Order header Order number Plant Production scheduler Operation sequences Standard sequence Other sequences Operations Work center Control key Standard values Capacity splits Individual machine Individual person SAP AG 1999 Settlement rule Settlement profile Settlement receiver Document links Material components Material number Quantity Reqmts date Doc. number Doc. category Prod. resources/tools PRT number PRT category Number Trigger Points Functions Confirmations Quantities Times Costs Planned Actual The order structure can be enhanced by adding certain elements. At least one operation is required. The system automatically creates this operation when missing. You have the choice of whether or not to assign material components, production resources / tools and trigger points to the operation. You can create several (parallel) operation sequences. You can make a selection from several alternative sequences. Suboperations are permitted within an operation. Costs are determined at operation level and submitted at order header level only in the case of order-related cost object controlling. (C) SAP AG LO215 3-4
36. Production Order - Header Definition Origin Product (activity) to be manufactured with the order Order Functions Edit Goto Header Environment 1000767 Manual Planned order General Assignment Goods receipt Control Dates/quantities Master data SAP AG 1999 Order type Order number Plant Material or activity Quantities dates To Routing To BOM To Costing Entered by / Changed by Plants Assignments MRP controller Control of goods receipt Movement type Settlement rule Settlement receiver Percentages Deadline monitoring Quantity monitoring The segment of the order header describes the product that is to be manufactured with the production order (finished product, assembly, individual part). There are a series of detail screens for the order header. The header text of a production order can either be the short text of the material master or the header text of the routing that has been copied into the production order (with reference to this, see the switch in table T399X). (C) SAP AG LO215 3-5
37. Production Order - Operation Definition Origin Types General Data Single step in Order Order Functions Edit Goto Operation Environment 1000767 Manual Routing Operation Suboperation Stand. values Ext. processing Interoperation times Standard value calc. General Data Operation 0010 SAP AG 1999 Operation overview Standard values Ext. processing Interoperation times Standard values calc. Splitting Overlapping Operation dates User fields Quantities/activities Confirmed dates This segment of the operation describes the individual work steps of the production order. There are a series of detail screens for an operation. These screens, in turn, incorporate further detail screens. For example, you can branch from the component overview to screens for each material component. You have the option of inserting suboperations hierarchically with reference to an operation. This enhances calculation and capacity planning. The operation control key of the sub-operation plays an important role in this. Scheduling always occurs at operation level. The standard values of the suboperations can be cumulated on the corresponding operation when the dimension and units of measurement are the same. It is not possible to assign material components or production resources / tools to sub-operations. (C) SAP AG LO215 3-6
38. Production Order - Material Components Definition Origin Materials required for an operation or for manufacturing a product Order Functions Edit Goto Component Environment 1000767 Manual BOM Planned order Purch.data VarSzeltmDta Co-product Text item General data Compon. 0010 SAP AG 1999 Material number Material description Requirements qty Reqmts date Reservation Item category Bulk mat. indicator Available quantity Issued quantity Missing parts quantity Text editor In a production order, you can assign any number of material components to an operation. The segment for the material component describes the material required to carry out the individual operations. There are a series of single screens for a material component. (C) SAP AG LO215 3-7
39. Production Order - Production Resources/Tools Definition Production resources/tools required Material to execute an operation Equipment (as of 3.0) Document Other Order Functions Edit Goto PRTs Environment 1000767 General Quantities Dates Item 0010 SAP AG 1999 Origin Types PRT number PRT control key Plant Requirements qty Usage value Formulas Usage dates Document (graphics) PRT text Manual Routing In a production order, you can assign any number of production resources/tools to an operation. The segment for production resources/tools describes the required devices, tools, test equipment and so on required for executing an individual operation. The production resources/tools category is essentially derived from the demands on a production resource/tool and its relationship to a certain object (material, equipment and so on). (C) SAP AG LO215 3-8
40. Production Order - Documents Definition Production resources/tools required execute an order Origin Manual Material Master Bill of Material Prod.Version Order Processing Functions Go to Document Environment P-100 Document 000 00 Doc. Data Additional Data Descriptions Object Links Original Originals SAP AG 2003 Document no. Subdocument Document version Assignmt to operation Origin Format Object link Original appl. file(s) Storage data You can assign any number of documents to a production order. These are maintained in the Document Management System (DMS). The documents themselves are only linked to the production order and not saved in it. You can create links from documents to a production order manually or automatically. Documents can be drawings, texts, videos and so on. Application example: Product descriptions Assembly instructions and diagrams Inspection instructions and certificates Work instructions Storage and transportation regulations Spare parts lists Maintenance regulations (C) SAP AG LO215 3-9
41. Production Order - Costs Definition Origin Costs arising during the execution of a production order Order Functions Edit Goto Header Environment 1000767 Itemization Cost categories Cost comp. structure SAP AG 1999 Automatic Costing Material costs Stock material Price determination according to valuation variant Non-stock material Price from purch. info record Production costs In-house production Activity price according to valuation variant Ext. processing Price acc. to valuation variant Process costs Assigned acc. to template Overhead costs Calculated in overhead structure If order-related cost object controlling is used, each individual production order has a cost object (CO). Order costs can be calculated manually or automatically. You define this by setting up the order-type dependent parameters accordingly in Customizing (table T399X). The CO object enables you to display different lists of costs for a production order. By choosing Goto + Costs in an order, you can find lists for the terms Itemization (detailed overview of the individual costing items) Analysis (overview structured according to cost category) Cost component structure (overview structured according to arithmetical cost components) (C) SAP AG LO215 3-10
42. Production Order - Settlement Rules Order header Oppeerraattiioonnss Maatteerriiaall ccoomppoonneennttss PPrrood.. rreessourrcceess//ttooollss Costs Planned SAP AG 1999 Target Actual 20 50 100 Definition Receiver of order costs Account assignment categories Material Cost center CO order Asset WBS element Sales order and so on Origin Manual Automatic You control order settlement by way of settlement rules. The order can be settled proportionally to one or more receivers. Settlement rules are created manually or automatically (during order creation). At the latest, they must be maintained before the goods receipts posting is carried out for the material to be produced. You define the settings for order settlement in Customizing. If you use product-related cost object controlling, the settlement rules are contained in the product cost collector and not in the production order. (C) SAP AG LO215 3-11
43. Processing a Production Order Archiving / deleting Order settlement Calculate variances Goods receipt 12 13 10 11 14 Orrderr headerr Operations Material components Prod. resources/tools Costs Planned 100 Determine WIP Confirmations SAP AG 1999 1 Order request Order creation Availability checks Machine reservation Order release Print order 3 4 5 Material staging 20 50 Target Actual 8 Order processing 2 6 7 9 The production order runs through a wide range of individual activities. WIP calculation, variance calculation and settlement are generally periodic operations for cost object controlling that are processed in the background. You must define a series of settings for each individual stage if an order is to be processed successfully. CO Configuration includes a special feature that sets the prerequisites for WIP determination, variance calculation and settlement. (C) SAP AG LO215 3-12
44. Order Structure and Processing: Summary SAP AG 1999 You have gained an overview of the data structure of a production order You know the most important production order screens The basic functions of production order management were shown in an example (C) SAP AG LO215 3-13
45. Exercise Data Note: There will not be sufficient time to work through all the exercises during the course. The exercises marked Optional should be seen as supplementary examples that can be used, as required and time permitting, during the course. Attendees can also use these exercises after the course, to consolidate what they have learned. Explanation of the Symbols in the Exercises and Solutions Exercises Solutions Course Objectives Business scenario Tips & Tricks Warning or caution (C) SAP AG LO215 3-14
46. Data in the exercises Type of data Data in training system (ID3, client 400) Data in the IDES system (ID3, client 800) Group no. xx (01....20) User master records LO215-xx password FERT Client 400 (401, 402) as per training room Customizing project 200 200 Company code 1000 1000 Business area 1000 1000 Purchasing 1000 1000 organization Sales organization 1000 1000 Distribution channel 10 Final customer sale 10 Final customer sale Division 00 Multiple division 00 Multiple division Sector M Mechanical engineering M Mechanical engineering Personnel area 1000 1000 Personnel subarea Chart of accounts INT INT Controlling area 1000 1000 Cost center hierarchy H1 H1 Cost center nodes 4200 4200 (C) SAP AG LO215 3-15
47. Cost centers 4210, 4220, 4230 4210, 4220, 4230 Activity types 1410 Machine time 1420 Setup time 1430 Personnel time 1410 Machine time 1420 Setup time 1430 Personnel time Factory calendar 01 01 Plants 1000 (Normal) 1100 (special structures) 1000 (Normal) 1100 (special structures) MRP controllers 100, 101 Demo 001 to 002 Participants 099 Instructor 100, 101 Demo Capacity planner 100, 101 Demo 001 to 002 Participants 099 Instructor 100, 101 Demo Production scheduler 100, 101 Demo 001 to 002 Participants 099 Instructor 100, 101 Demo Production scheduling profile 0000001 Normal 0000002 automatic 0000001 Normal 0000002 automatic (C) SAP AG LO215 3-16
48. Work centers T-Exx T-Fxx T-Lxx T-Mxx T-Pxx T-Vxx T-WM 1111 1112 1116 1117 1310 1320 1721 1904 1905 1906 T-Exx T-Fxx T-Lxx T-Mxx T-Pxx T-Vxx T-WM 1111 1112 1116 1117 1310 1320 1721 1904 1905 1906 Material (see also following BOM structure for T-F1xx) T-F1xx Product T-B1xx Assembly 1 T-B2xx Assembly 2 T-B3xx Assembly 3 T-B4xx Assembly 4 T-T1xx Indiv.comp 1 T-T2xx Indiv.comp 2 T-T3xx Indiv.comp 3 T-T4xx Indiv.comp 4 T-T5xx Indiv.comp 5 P-100 100-100 100-200 100-300 100-400 100-110 100-120 100-120 100-310 100-210 (C) SAP AG LO215 3-17
49. Normal flow Collective order Config.var. scn. 1 Config.var. scn. 2 Config.var. scn. 3 Change management Normal flow Rework Automat. Procedure Limited no. of Variants W/o BOM and plan Select. BOM/plan Op. consequences Co-products Mat. components Mat. staging Availability Discontinued parts Cross-plant Split valuation Batch production Ext. Proc. / proc. Serial numbers Repetitive /order-based production Stock determination P-100 P-400 P-500 P-501 P-502 P-600 100-300 100-301 T-A T-V1, V2 T-MAN T-SEL T-OS T-COP T-MC T-MS T-MA T-MD T-PDP T-MV T-BCH T-EX T-SN T-REP T-STOCK P-100 P-400 P-500 P-501 P-502 P-600 100-300 100-301 T-A T-V1, V2 T-MAN T-SEL T-OS T-COP T-MC T-MS T-MA T-MD T-PDP T-MV T-BCH T-EX T-SN T-REP T-STOCK (C) SAP AG LO215 3-18
50. Bills of material T-F1xx P-100 P-400 P-500 P-501 P-502 P-600 T-A T-V1, V2 T-SEL T-OS T-COP T-MC T-MS T-MA T-MD T-PDP T-MV T-BCH T-EX T-SN T-REP P-100 P-400 P-500 P-501 P-502 P-600 T-A T-V1, V2 T-SEL T-OS T-COP T-MC T-MS T-MA T-MD T-PDP T-MV T-BCH T-EX T-SN T-REP Routings T-F1xx P-100 P-400 P-500 P-100 P-400 P-500 (C) SAP AG LO215 3-19
51. P-501 P-502 P-600 T-A T-V1, V2 T-SEL T-OS T-COP T-MC T-MS T-MA T-MD T-PDP T-MV T-BCH T-EX T-SN T-REP 50000003 standard task list P-501 P-502 P-600 T-A T-V1, V2 T-SEL T-OS T-COP T-MC T-MS T-MA T-MD T-PDP T-MV T-BCH T-EX T-SN T-REP 50000003 standard task list WM storage bin PROD-1310 PROD-1310 Standard trigger point T-NACHARB T-NACHARB Order types PP01 Demo and exercise PP03 Demo and exercise PP04 Demo and PP01 Demo PP03 Demo PP04 Demo PP06 Demo (C) SAP AG LO215 3-20
52. exercise PP06 Demo and exercise PP07 Demo and exercise PP08 Demo and exercise PP07 Demo PP08 Demo (C) SAP AG LO215 3-21
53. PP Exercise Material - BOM T-F1xx Item 0010 0020 0030 0040 Pos. 0010 0020 0030 0010 0010 0010 1 1 8 SAP AG 1999 T-F1xx (FERT, P-100) (1000, 0, _ ) 1 0050 (C) SAP AG LO215 3-22 T-T1xx (ROH, 100-110) (1000, 1000, 2 ) T-T2xx (ROH, 100-120) (1000, 1000, 2 ) T-T3xx (ROH, 100-130) (1000, 1000, 2 ) 1 T-T4xx (ROH, 100-310) (1000, 1000, 2 ) 1 T-B1xx (HALB, 100-100) (1000, 10, 2 ) 1 T-B2xx (HALB, 100-200) (1000, 10, 2 ) (1100, 10, 2 ) 1 T-B3xx (HALB, 100-300) (1000, 0, _ ) 1 T-B4xx (HALB, 100-400) (1000, 10, 2 ) T-T0xx (ROH, 100-210) (1000, 1000, 2 ) (1100, 1000, 2 ) Key: (Material, IDES template) (Plant, stock qty, sec. reqmts ind.)) 1 T-T5xx (ROH, 100-410) (1000, 1000, 2 ) 1 Dokument T-F1xx DRW, 000, 00
54. PP Exercise Materials - Routings T-F1xx(FERT, P-100) (1000, 0, _ ) 0010 0020 T-F2xx(FERT, P-100) (1000, 0, _ ) T-Vxx ( 1320 ) 0030 T-Lxx 0040 T-Exx 0050 0060 T-Pxx SAP AG 1999 titel (author) 2 not assigned 10 TP-T-Mxx Lxx ( 1310 ) ( 1906 ) ( 1904 ) T-Fxx ( 1721 ) ( 1721 ) Assignment to stat. work c enter and hierarc hy T-VH hierarchy: T-V T-EH hierarchy: T-E (C) SAP AG LO215 3-23
55. Order Structure and Order Processing Exercises Unit: Order Structure and Order Processing Topic: Order Structure and Order Processing (LO215 Exercise 1) • Structure (data and contents) of a production order In your capacity as production manager, production scheduler, supervisor or operator, you work with production orders all the time. In this exercise, you will become familiar with the structure of a production order. 1-1 Display the production order no. _______________ . Path: S000 ® LO ® PP ® SFC ® ORDER ® DISPLAY 1-2 Display the individual data segments, screens and their data fields in the following order: Note any questions you may have about the meaning of the data fields. If the meaning of any of the data fields is not clear, ask the instructor. 1-2-1 Order header screens Path: ® GOTO ® HEADER (C) SAP AG LO215 3-24
56. Select the corresponding tab index for the respective screen. General Assignment Goods receipt Control Dates/quantities Master data Long text Settlement rule Path: ® HEADER ® SETTLEMENT RULE 1-2-2 Overview of the operation sequences Path: ® GOTO ® OVERVIEWS ® SEQUENCES 1-2-3 Operation sequence details Path: ® SEQUENCE ® DETAILS 1-2-4 Operation overview Path: ® GOTO ® OVERVIEWS ® OPERATIONS 1-2-5 Operation screens (select operation "0010") Path: ® OPERATION ® OPERATION DETAILS (C) SAP AG LO215 3-25
57. Select the corresponding tab index for the respective screen. General Standard values External processing Interoperation times Standard value calculation Splitting Overlap Dates User fields Suboperation/dates Quantities/activities Confirmed dates Qualification Long text 1-2-6 Material components - Overview Path: GOTO ® OVERVIEWS ® COMPONENTS 1-2-7 Material component screens (select component "0010" or "0070") Path: COMPONENT ® COMPONENT DETAILS Select the corresponding tab index for the respective screen. Item ’0010’ General Data Item ’0070’ VarSzeltmDta 1-2-8 Overview of production resources/tools for operation "0050" Path: Go to the operation overview and select operation "0050". In the menu bar at the bottom of the screen, select the PRT pushbutton (Production resources/tools) 1-2-9 Screens for the production resources/tools (select production resource/tool "0020") (C) SAP AG LO215 3-26
58. Path: PRODUCTION RESOURCE/TOOL ® PRODUCTION RESOURCE/TOOL DETAILSHILFSMITTEL Select the corresponding tab index for the respective screen. Item ’0020’ General Quantities Dates 1-2-10 Document overview Path: GOTO ® OVERVIEWS ® DOCUMENTS 1-2-11 Display of the document information record (select the first document) Path: DOCUMENT ® DISPLAY DOCUMENT INFORMATION RECORD Select the corresponding tab index for the respective screen. Document data Additional data Descriptions Object links Original 1-2-12 Display of the original document (display both originals from the document overview for the order) Path: DOCUMENT ® DISPLAY ORIGINAL DOCUMENT 1-2-13 Costs Itemization Analysis (Cost categories) Cost comp. structure (Cost component (C) SAP AG LO215 3-27
59. Path: GOTO -> COSTS -> ITEMIZATION ® ANALYSIS ® COST COMP. STRUCTURE (C) SAP AG LO215 3-28
60. Order Structure and Order Processing Solutions Unit: Order Structure and Order Processing Topic: Order Structure and Order Processing (LO215 Exercise 1) No answers are required for this exercise. (C) SAP AG LO215 3-29
61. Order Creation/Order Change: Contents Function procedure "Creating an order" Automatic follow-on postings Creation variants Normal With production version No reference to material (any activity) Copy from order Related to sales order With variant configuration Bill of material and task list selection Converting planned orders Reading master data Operation sequences in an order SAP AG 1999 (C) SAP AG LO215 4-1
62. Order Creation/Changing Orders: Course Objectives SAP AG 1999 At the conclusion of this unit you will be able to: Define the basic features and variants for creating production orders Describe subsequent functions in order creation Describe the process of routing and BOM selection when creating an order Define how master data is read into existing orders Describe how to create and convert planned orders (C) SAP AG LO215 4-2
63. Overview Diagram (4) Introduction 1 Overview 2 Order Structure / Processing 3 4 Order Creation / Order Change Order Release 5 Printing Order Documents 6 Material Staging 7 SAP AG 1999 Order Control 8 Confirmations 9 Goods Receipt 10 Settlement, Archiving and Deletion 11 Information Systems 12 Mass Processing and Automation 13 Collective Orders 14 (C) SAP AG LO215 4-3
64. Creating Production Orders Manual Requirements planning Automatic Optional (Customizing) SAP AG 1999 Friday July 27 1992 Tuesday December 18 1992 Specify order type Define order item Copy routing Copy bill of material Lead time scheduling Availability check Various functions (1) Add, change Save production order The production order can be generated automatically (confirmation, sales order) or manually (directly) by converting it from a planned order. A start / finish date is entered for the order item (product) according to the scheduling type (forwards or backwards) . Lead time scheduling is executed automatically. It calculates the start / finish dates of the order and the detailed dates and capacity requirements of the operations. You also have the option of carrying out an availability check (specifiable in Customizing). You can determine the planned costs when saving the order (specifiable in Customizing). ((11)) Other functions that can be executed automatically are: Batch creation, determination, order classification, serial number assignment, document integration. (C) SAP AG LO215 4-4
65. Automatic Postings SAP AG 1999 Material reservations Purchase requisitions Costs (CO object) Capacity requirements Transport requirements Inspection lots PRT requirements Inventory management Purchasing Controlling Capacity planning Warehouse management Quality management PRT management When you create a production order, a series of additional posting procedures occur at the time of posting (the data is already formatted online). These automatically generate the required data for stored parts of the system. Material reservations are generated for all warehouse components. You can choose whether these reservations are to be immediately relevant to MRP or not until the time of release (indicator in the order-type dependent parameters T399X) Purchase requisitions are created for non-warehouse components and externally processed operations. Costs are determined when you save. Transport requirements are generated when the operation is released. PRT requirements are only generated internally. At the present time, however, there is no requirements planning for PRTs which works with these records. Transaction CF21 (using PRT in orders) is available for evaluating PRT requirements in production orders. Missing parts records are written for missing parts. (C) SAP AG LO215 4-5
66. Creation Variants 1 With reference to material Directly (manually) From planned order Copy from order For sales order From SD (assembly order) From confirmation (rework) As collective order With variant configuration Without reference to material Activity SAP AG 1999 20 50 Material components Prod. resources/tools 100 Order header Operations Planned Target Actual Costs There are numerous possibilities for creating production orders. (C) SAP AG LO215 4-6
67. Creation Variants 2 Create without routing and bill of material Create with routings Planned SAP AG 1999 Order Order Create with routing and bill of material Planned Order Material BOM Create with planned order Planned order Order Planned Operations, material components and production resources / tools are normally copied from the routing and BOM. You can also input such information manually. The BOM is not reread when you convert a planned order. If you do not specify otherwise in a routing, the system automatically assigns the BOM components to the first operation. (C) SAP AG LO215 4-7
68. Scheduling in Production Planning Material requirements planning Own scheduling for planned orders To the day Calculated basic dates Basic start date Base in-house production time or replenishment lead time Advantageous for performance No capacity requirements are determined Lead time scheduling for orders and routings Used To the second Starts from basic dates Requirements planning Determined production dates (scheduled dates) Base operations Determined capacity requirements SAP AG 1999 Basic finish date Creation date Manual Start date Finish date Release date Periods OOrrddeerr hheeaaddeerr Operati ons Material com pone nts Prod. res ource s/tool s Cost s Pla nned Tar get Act ual 20 50 100 Production planning has two scheduling methods that are used differently and have different results: Scheduling of planned orders in material requirements planning (calculates the basic dates only) Lead time scheduling (starts from the basic dates and calculates the production dates) Only lead time scheduling calculates operation-related dates and capacity requirements. Lead time scheduling is the basis for Order scheduling Routing scheduling Scheduling in applications PS, PM, PI In addition, lead time scheduling can be activated in material requirements planning in order to determine capacity requirements for planned orders. (C) SAP AG LO215 4-8
69. Scheduling/Time Elements of an Order Float bef.prod. Op. 0010 Op. 0020 Op. 0030 Op. 0040 ........ Op. 0099 Float after production GR proc.time Pick/pack time Loading time Transit time PS SS Queue time Setup time SF PF AD LT GI RDD Proc. timeTeardown Wait time Move time ES LS EF LF Order dates Operation dates Time concepts PS Planned start date (basic start date) SS Production start date (scheduled start date) SF Production finish date (scheduled finish date) PF Planned finish date AD Planned availability date LT Loading time GI Goods issue date RDD Requested delivery date SAP AG 1999 ES Earliest start date LS Latest start date EF Earliest finish date LF Latest finish date Lead time of order or operation Float times for order/operation Execution time of operation Interoperation times Processing times in sales The slide shows all possible elements of the total lead time of a production order. There are two order float times, which serve different purposes. Float before production - Postponement of dates, capacity planning Float after production - Absorbs any delays The order float can be predefined using a scheduling margin key (order header screen). This key is entered in the material master and maintained in Customizing for Shop Floor Control by choosing "Scheduling". The duration of an operation is made up of a maximum of five time elements. Queue time Setup time Processing time Teardown Minimum wait time The duration of the move time is the time between two operations but it is assigned to the preceding operation. If a production order is being used to carry out production for a sales order (for example, assembly of a finished product), then other time segments that are relevant to sales have to be added to these. (C) SAP AG LO215 4-9
70. Number Assignment for a Production Order Range from to Assignment internal external(x) Assignment of the order types (element) SAP AG 1999 . . . . Number range object for an order (general) Number range - Group 1 1000000 1999999 Number range - Group 2 2000000 2999999 Number range - Group 3 3000000 3999999 X PP02 PI02 . .. . . . PP01 IDES PP06 . .. . . PI01 . . . . . . Order numbers are assigned according to order type. Numbers can be assigned either externally or internally. The order number can be composed of a maximum of 12 characters. Order numbers can be defined independent of company codes, plants and other organizational structures. A number range group must be specified for each predefined number range. You can create an unlimited amount of number range groups. The order categories can be assigned to any of the number range groups. The system does not allow multiple assignment. The current status of the internal number assignment can be changed manually provided that the sequences are taken into account. You maintain the number range in Customizing. (C) SAP AG LO215 4-10
71. Task List Selection Criteria Selection type (T399X) "With / without routing" Task list usage Task list type Task list selection ID Usage "Production version" indicator (T399X) Material no. Plant "Alternative selection" indicator (MRP screen 4) Production version Group Group counter Status Validity Lot-size range Deletion flag = = "X" SAP AG 1999 "Routing required / optional" "Manual / automatic selection" "With / without ref. operation set" "P" (Production) "N" (Normal) "S" (Standard) (in reference operation sets) "Released" "Basic start/finish date" "Order quantity" Customizing A Material Routing You define the routing selection options in Customizing. The most important tables are: T399X order-type dependent parameters and TCA43 automatic selection You can determine whether a routing is necessary or not (selection type). All criteria are always checked and a routing is only selected if all criteria are fulfilled. Determining which validity the routing should be selected with is dependent on the setting in table T399D ( Customizing Requirements Planning). (C) SAP AG LO215 4-11
72. Task List Selection - Procedure PP parameters for order type (T399X) "Task list selection" Select a task list? = Yes Automatic selection ? = No indicator Manual selection Key: PV = Production version SAP AG 1999 = No = Yes Mat. master "Alternative selection" indicator PP parameters for order type (T399X) "ProdVersion" indicator = 3 Mandatory task list = 2 = 1 = Blank Create operation (default values from TCO41) Automatic routing selection (TCA43) Routing Routing Routing Additional criteria selection by PV Task list selection by production version Task list selection by selection ID (TCA43) Task list selection by selection ID (TCA43) During automatic selection, the alternative selection indicator in the material master (MRP screen 4) determines how selection is carried out. Note the following special features: IND = Blank Using the selection ID from table T399X, the system searches the sequence of priorities contained in table TCA43 for the first available routing that fulfills the criteria: lot size and task list category, usage and status. IND = 1 Same as for "blank". IND = 2 The system searches the material master for production versions that fit the lot size. If only one exists, then its routing is checked against all criteria (also those contained in TCA43!). If there are more than one, table T399X decides (production version indicator) whether the user (dialog box) or the system (automatic) determines which production version is to be selected. If, despite this, no valid routing is found, the system does not stop. The system carries on searching using the procedure for when the indicator is "blank". IND = 3 Same as for value = 2. If no valid routing is found in this case, the system stops the search! No production order is created. Selection according to production version presupposes that valid production versions have been maintained in the material master. (C) SAP AG LO215 4-12
73. If you create a routing for a sales order, then this is used independent of the other selection criteria. (C) SAP AG LO215 4-13
74. BOM HEADER ITEM ITEM SAP AG 1999 Stage 0 1 2 . . . Pre-assembled shaft . . . 20 50 Material components Prod. resources/tools 100 Pump P-100 Pre-assembled casing 100-100 100-300 Casing 100-110 Support base 100-700 Shaft 100-301 Orrdeerr heeaadeerr Operations Planned Targe t Actual Costs BOMs contain the material structure and required quantities of the individual components for a product. The required quantities are not dependent on the order. BOM data is copied to the production order. Subsequent changes you make to the BOM do not take effect on orders that already exist. When you create an order, a BOM is chosen on the basis of the corresponding selection criteria. The BOM is exploded on one level. An exception to this is multi-level BOM explosion for so-called phantom assemblies. Subitems are not copied to the order. (C) SAP AG LO215 4-14
75. Bill of Material Selection - Criteria BOM header BOM item SAP AG 1999 Customizing BOM application (T399X) BOM selection ID BOM selection priority BOM alternative BOM usage "Alternative no." "Production version" indicator (T399X) "Automatic/manual" Material no. Plant "Alternative selection" indicator (MRP screen 4) Production version BOM status Validity Lot-size range Deletion flag "Released" "Basic start/finish date" "Order quantity" = = "X" Status Validity 'Production' A Material BOM You must define the BOM selection options in Customizing. The system always checks all criteria. Only BOM items relevant to production are copied to an order. (See the item category of the component). If there are several valid BOMs that could be selected, the system automatically chooses the first valid one. You can make the validity of a BOM item dependent on various parameters (for example, date, customer, serial and matieral number of the product to be manufactured). Refer to "Parameter Effectivity" in change management (C) SAP AG LO215 4-15
76. Bill of Material Selection - Procedure Mat. master Indicator "Alternative selection" = Blank = 1 = 2 BOM selection by BOM selection by BOM selection by = 3 PV permitted? Mandatory BOM selection by PV Key: PV = Production version SAP AG 1999 BOM usage priorities (TCS41) BOM alternative alternative (T415A) BOM BOM BOM Additional criteria = Yes = No = No = Yes BOM usage(TC04) Sel. ID Selection by date permitted ? Selection by PP parameters for order type (T399X) "BOM usage" lot size date PV PP parameters for order type (T399X) "ProdVersion" indicator During automatic selection, the alternative selection indicator in the material master (MRP screen 4) determines the selection procedure. Note the following special features: IND = Blank The system takes the BOM usage that is defined for each order type from table T399X, enters table TC04 with this and takes a selection ID from this table. The system uses this selection ID and searches the sequence of priorities contained in table TCS41 for the first available BOM that fulfills the lot size and BOM usage criteria. IND = 1 Selection according to date requires that an entry is maintained in Customizing for the material (T415A alternative selection multiple BOM). IND = 2 The system searches the material master for production versions that fit the lot size. If only one exists, then its BOM is checked against all criteria (also those contained in TCS41!). If there are more than one, table T399X decides (production version indicator) whether the user (dialog box) or the system (automatic) determines which production version is to be selected. If, despite this, no valid BOM is found, the system does not stop. The system carries on searching using the procedure for when the indicator is "blank". IND = 3 Same as for value = 2. If no valid BOM is found in this case, the system stops searching! The production order has no components. (C) SAP AG LO215 4-16
77. Selection according to production version presupposes that valid production versions have been maintained in the material master. (C) SAP AG LO215 4-17
78. Item Categories in the Production Order Order header Operations Material components Prod. resources/tools Costs SAP AG 1999 20 50 100 Reservation Purchase requisition Find object for class Planned Target Actual Stock item Variable-size item Non-stock item Text item Class item Item categories control the data scope and functions of a material component. Typical examples are: Stock item Non-stock item Variable-size item Text item Class item You cannot make alterations to item categories once they have been set. Follow-on documents are generated with the production order according to item category. Components with the item category "non-stock item" automatically generate a purchase requisition. This can be displayed for an item via a further screen. The class item stands for a wide variety of different materials. When you enter the command "find object function for class", the system can specify the class item in a particular stock item. The "document item" is transferred to the document list of the production order (document link) (C) SAP AG LO215 4-18
79. Reservation Reservation IItteemm SAP AG 1999 1 Assignment Base date Check calendar A Material Material Plant / Storage location Reqmts date Movement allowed Committed qty Header IItteemm IItteemm The system generates material reservations for all material components of a production order of the type "stock material". Reservations are taken into account when determining the conditions for material requirements planning. Reservations are also taken into account when creating goods movements for components of the production order. A reservation item applies to a plant or a plant's storage location. A requirements date is defined by the order for each item. You can control whether goods movements are allowed for the reservation item by means of an indicator. The reservations for material components of the production order are assigned to this production order. You can compile lists of reservations for the material or account assignment (production order). (C) SAP AG LO215 4-19
80. Material Assignment SAP AG 1999 Routing BOM Item 10 Item 20 Op. 10 Op. 20 Op. 30 B Material A Material You can assign material components to operations both when managing BOMs and routings. The assignment of material components to operations is copied to the production order. If no assignments are maintained, then the system automatically assigns the BOM material components to the leading operation. When you display the material components overview, you can assign material components to individual operations and display material components. The material components list can be sorted and filtered according to various criteria in order to enhance this overview. Other functions include: Assigning, reassigning and deleting material assignments. Navigating between operations You are able to reassign materials up to the point of order release. (C) SAP AG LO215 4-20
81. Assignment of Production Resources / Tools SAP AG 1999 Production order Op. 10 Op. 20 Op. 30 PRT1 PRT2 You can assign production resources/tools to every operation in a production order. Production resource/tool assignments are copied from the routing to the production order. (C) SAP AG LO215 4-21
82. Document Integration in Production Orders Master Data DMS B Material BOM Routing Material item 10 Document item 20 Document item 30 Operation 10 Operation 20 Order item Overview of documents in PrO Fri Fri Document 4 Document 5 Document link 1 Document link 2 Document link 4 Document link 5 Operation 10 Operation 20 Material item 10 Fri Fri Prod. res./tools Production res/tools SAP AG 2003 Production order Document Management System (DMS) Document 1 Document 2 Document 3 Document 6 You can assign any number of documents to a production order. These are maintained in the Document Management System (DMS). Documents can be drawings, texts, videos and so on. The documents themselves are only linked to the production order and not saved in it. You can create links from documents to a production order manually or automatically. Automatic linking of documents takes place during order creation or release. The document items are copied from the BOM, the production version or from the document link to the material master of the product to be manufactured. (This must be activated in the production scheduling profile - Customizing for Shop Floor Control) Document links in the production order created in this way can be displayed, changed, deleted, printed (separate list), archived and displayed in the product structure browser. Original documents cannot be printed out. All document types that you use must be permitted for object PORDER (production order), work with status management and must be released. (See Customizing for the Document Management System). Examples, see above: Document 1 Link copied from material master Document 2 Link created manually Document 3 No link to production order Document 4 and 5 Link created from BOM item Document 6 does not appear in the document overview of the production order (C) SAP AG LO215 4-22
83. Operation Sequences in a Production Order Order he
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