Production Planning and Control with SAP

Production Planning and Control with SAP

Hardback SAP Press

By (author) Jörg Thomas Dickersbach, By (author) G. Keller

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  • Publisher: SAP Press
  • Format: Hardback | 525 pages
  • Dimensions: 184mm x 236mm x 40mm | 1,085g
  • Publication date: 20 December 2010
  • Publication City/Country: Maryland
  • ISBN 10: 1592293603
  • ISBN 13: 9781592293605
  • Edition: 2, New edition
  • Edition statement: 2nd New edition
  • Sales rank: 461,918

Product description

Serves as an up-to-date, comprehensive guide to discrete manufacturing with Production Planning in SAP ERP Explains the business processes and customization steps for Production Planning Includes a new chapter on special forms of procurement This new, expanded edition is your must-have guide for implementing and using Production Planning (PP) in the SAP system. You ll learn about the different customizing processes of PP in detail from business fundamentals to integration with SAP SCM (APO) and everything you need to know about discrete manufacturing using SAP ERP. The book is based on the current release of SAP ERP (6.0), but is also suited for users of older releases. Processes and Customizing Learn about the processes of discrete manufacturing and its mapping in PP. Each chapter describes the business background and then walks you through the required configuration steps in the SAP system. Practical Presentation Develop a comprehensive understanding of production planning and control with SAP ERP and the tools you need for a successful implementation, with the help of the real-world, practical examples presented throughout. Use the Various SAP ERP Tools Master the various PP topics, including demand management, material requirements planning, long-term planning, capacity planning, SAP SCM, and much more. Special Procurement Forms This revised and expanded edition has been completely updated and supplemented with a completely new chapter on the topic of special procurement forms.

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Table of contents

* ... Foreword ... 13 * 1 ... Introduction ... 15 * 1.1 ... Goal of This Book ... 15 * 1.2 ... Target Audience ... 16 * 1.3 ... Structure and Content ... 16 * 1.4 ... Restrictions ... 17 * 2 ... Tasks in Industrial Operations ... 19 * 2.1 ... Technical Tasks ... 19 * 2.1.1 ... Development and Design ... 19 * 2.1.2 ... Work Scheduling ... 23 * 2.1.3 ... Programming ... 26 * 2.1.4 ... Quality Management ... 30 * 2.1.5 ... Production Execution ... 33 * 2.2 ... Business Tasks ... 35 * 2.2.1 ... Sales and Distribution ... 35 * 2.2.2 ... Product Cost Planning ... 38 * 2.2.3 ... Materials Management ... 40 * 2.2.4 ... Purchasing ... 42 * 2.2.5 ... Production Planning ... 43 * 2.3 ... The Production Area in Industrial Operations ... 45 * 2.3.1 ... Production in Computer Integrated Manufacturing ... 45 * 2.3.2 ... Production as Part of Logistics ... 48 * 2.4 ... Characteristics of Production Type Creation ... 52 * 2.4.1 ... Product Standardization ... 52 * 2.4.2 ... Product Structure ... 53 * 2.4.3 ... Production Type ... 55 * 2.4.4 ... Production Organization ... 56 * 3 ... Production Planning and Control in SAP ERP ... 59 * 3.1 ... PP in the Context of SAP ERP ... 59 * 3.2 ... Processes in Production Planning and Control ... 62 * 3.3 ... Production Types ... 64 * 3.3.1 ... Discrete Manufacturing ... 65 * 3.3.2 ... Repetitive Manufacturing ... 65 * 3.3.3 ... Process Manufacturing ... 70 * 3.3.4 ... Kanban ... 72 * 3.3.5 ... Engineer-to-Order Production ... 76 * 4 ... Organizational Structures ... 79 * 4.1 ... Meaning of Organizational Structures ... 79 * 4.2 ... Organizational Structure Overview in SAP ERP ... 81 * 4.3 ... Planners in Design and Work Scheduling ... 86 * 4.4 ... MRP Controller, Capacity Planner, and Production Scheduler ... 87 * 5 ... Master Data ... 91 * 5.1 ... Master Data Overview ... 91 * 5.2 ... Material ... 92 * 5.3 ... BOM ... 100 * 5.3.1 ... Areas of Use and Types of BOMs ... 100 * 5.3.2 ... Material BOM ... 103 * 5.4 ... Work Center ... 112 * 5.4.1 ... Role of the Work Center ... 112 * 5.4.2 ... Basic Data for the Work Center ... 113 * 5.4.3 ... Capacity ... 115 * 5.4.4 ... Formulas for Capacity Load and Scheduling ... 121 * 5.4.5 ... Costing ... 125 * 5.4.6 ... Work Center Hierarchy ... 126 * 5.5 ... Routing ... 129 * 5.5.1 ... Purpose and Structure of the Routing ... 129 * 5.5.2 ... Routing ... 136 * 6 ... Sales and Operations Planning ... 147 * 6.1 ... Process Overview ... 147 * 6.2 ... Basic Technical Principles in Sales Planning ... 154 * 6.2.1 ... Information Structures ... 154 * 6.2.2 ... Planning Methods ... 158 * 6.2.3 ... Product Group ... 161 * 6.2.4 ... Planning Hierarchy ... 163 * 6.2.5 ... Proportional Factors and Disaggregation ... 167 * 6.2.6 ... Versioning ... 169 * 6.3 ... Planning Table ... 170 * 6.3.1 ... Planning Type ... 170 * 6.3.2 ... Macros ... 174 * 6.3.3 ... Planning in the Planning Table ... 176 * 6.4 ... Forecast ... 185 * 6.5 ... Event ... 191 * 6.6 ... Resource Leveling Using a Rough-Cut Planning Profile ... 194 * 6.7 ... Transferring Planning Data to Demand Management ... 198 * 6.8 ... Mass Processing ... 200 * 7 ... Demand Management ... 205 * 7.1 ... Process Overview ... 205 * 7.2 ... Time-Based Disaggregation ... 209 * 7.3 ... Planning Strategy ... 211 * 7.3.1 ... Selected Planning Strategies ... 211 * 7.3.2 ... Consumption ... 215 * 7.3.3 ... Planning Segments ... 216 * 7.3.4 ... Planning Strategy and Requirements Class ... 217 * 7.4 ... Editing Planned Independent Requirements ... 221 * 7.4.1 ... Reducing the Planned Independent Requirements ... 223 * 7.4.2 ... Reorganization of Planned Independent Requirements ... 224 * 8 ... Material Requirements Planning ... 225 * 8.1 ... Process Overview ... 225 * 8.2 ... Influencing Factors in Material Requirements Planning ... 230 * 8.2.1 ... Lot Size ... 230 * 8.2.2 ... Scrap ... 240 * 8.2.3 ... Safety stock ... 244 * 8.2.4 ... Master Data Selection ... 245 * 8.3 ... MRP Procedures ... 246 * 8.3.1 ... Material Requirements Planning ... 249 * 8.3.2 ... Consumption-Based Planning ... 251 * 8.3.3 ... Consumption Forecast ... 259 * 8.4 ... Executing Material Requirements Planning ... 262 * 8.4.1 ... Net Requirements Calculation Logic ... 262 * 8.4.2 ... Parameters for Material Requirements Planning ... 267 * 8.4.3 ... Planning Scope ... 271 * 8.5 ... Scheduling ... 272 * 8.5.1 ... Forward and Backward Scheduling ... 272 * 8.5.2 ... Scheduling In-House Production (Basic Date Determination) ... 273 * 8.5.3 ... Scheduling External Procurement ... 276 * 8.5.4 ... Planning Time Fence ... 278 * 8.6 ... Procurement Proposals ... 280 * 8.6.1 ... Planned Order and Purchase Requisition ... 280 * 8.6.2 ... Interactive Planning ... 283 * 8.7 ... Analysis ... 285 * 8.7.1 ... Stock/Requirements List and MRP List ... 285 * 8.7.2 ... Exception Messages ... 288 * 8.8 ... Plant Parameters and MRP Group ... 290 * 9 ... Special Forms of Procurement ... 295 * 9.1 ... Process Overview ... 295 * 9.2 ... Phantom Assemblies ... 297 * 9.3 ... Direct Production and Direct Procurement ... 300 * 9.4 ... Stock Transfer ... 309 * 9.5 ... Withdrawal from Alternative Plant ... 313 * 9.6 ... Production in Alternative Plant ... 314 * 9.7 ... Subcontracting ... 317 * 9.8 ... Consignment ... 322 * 10 ... Long-Term Planning ... 323 * 10.1 ... Process Overview ... 323 * 10.2 ... Planning Scenario ... 325 * 10.3 ... Executing Long-Term Planning ... 331 * 10.3.1 ... Release and Planning File Entries ... 331 * 10.3.2 ... Material Requirements Planning in the Planning Scenario ... 331 * 10.3.3 ... Evaluating the Planning Scenario ... 332 * 10.3.4 ... Transferring the Planning Scenario ... 334 * 11 ... Production Order Creation ... 337 * 11.1 ... Process Overview ... 337 * 11.2 ... Production Order ... 339 * 11.2.1 ... Order Type ... 346 * 11.2.2 ... Master Data Selection ... 348 * 11.2.3 ... Status and Trigger Point ... 352 * 11.3 ... Conversion from the Planned Order ... 357 * 11.4 ... Interactive Production Order Creation ... 359 * 11.5 ... Scheduling ... 361 * 11.5.1 ... Dates of the Production Order ... 361 * 11.5.2 ... Finite Scheduling ... 363 * 11.5.3 ... Transition Times ... 369 * 11.5.4 ... Splitting and Overlapping ... 371 * 11.5.5 ... Float Before Production and Safety Time ... 375 * 11.5.6 ... Reduction ... 377 * 11.6 ... Availability Check ... 379 * 11.6.1 ... Material Availability Check ... 380 * 11.6.2 ... Parameters for the Material Availability Check ... 383 * 12 ... Capacity Planning ... 389 * 12.1 ... Process Overview ... 389 * 12.2 ... Capacity Requirements and Capacity Evaluation ... 390 * 12.2.1 ... Capacity Requirements ... 390 * 12.2.2 ... Standard Evaluations of Capacity Utilization ... 392 * 12.2.3 ... Variable Evaluations of Capacity Utilization ... 394 * 12.2.4 ... Cumulating the Capacity Requirements ... 398 * 12.3 ... Checking Capacity Availability ... 400 * 12.4 ... Finite Scheduling ... 406 * 12.5 ... Dispatching ... 408 * 12.5.1 ... Profiles for Dispatching ... 410 * 12.5.2 ... Dispatching Sequence ... 417 * 12.5.3 ... Sequence-Dependent Setup ... 418 * 12.5.4 ... Midpoint Scheduling ... 423 * 12.5.5 ... Mass Processing ... 425 * 12.6 ... Capacity Planning Table ... 426 * 13 ... Production Execution ... 433 * 13.1 ... Process Overview ... 433 * 13.2 ... Releasing the Production Order ... 434 * 13.3 ... Material Withdrawal ... 438 * 13.3.1 ... Goods Issue Posting ... 438 * 13.3.2 ... Picking ... 440 * 13.3.3 ... Backflush ... 444 * 13.4 ... Confirmation ... 446 * 13.5 ... Goods Receipt ... 452 * 13.6 ... Settlement ... 456 * 13.7 ... Completion ... 457 * 14 ... Supply Chain Management and Integration with SAP APO ... 459 * 14.1 ... Supply Chain Management with SAP APO ... 459 * 14.2 ... Integration Scenarios ... 462 * 14.3 ... Technical Integration ... 464 * ... Appendices ... 469 * A ... Glossary ... 471 * B ... List of Abbreviations ... 501 * C ... Literature ... 503 * D ... List of Transactions ... 507 * D.1 ... Organizational Structure and Master Data ... 507 * D.2 ... Sales and Operations Planning ... 508 * D.3 ... Demand Management ... 509 * D.4 ... Material Requirements Planning ... 510 * D.5 ... Special Forms of Procurement ... 511 * D.6 ... Long-Term Planning ... 511 * D.7 ... Production Order Creation ... 512 * D.8 ... Capacity Planning ... 513 * D.9 ... Production Execution ... 515 * D.10 ... Integration with SAP APO ... 515 * E ... The Authors ... 517 * ... Index ... 519