SAP PP-PI: Basic Overview Guide

This document is a detailed guide that provides a basic understanding of the Production Planning for Process Industries (PP-PI) in SAP, primarily designed for batch-oriented process manufacturing in industries such as chemical, pharmaceutical, food and beverage, and batch-oriented electronics.

The document explains the concept of PP-PI, which supports integrated planning of production, waste disposal, and transport activities within a plant. It also facilitates the integration of plants within the company, both vertically through an information flow and horizontally through the coordination of planning between production plants, recycling and waste disposal facilities, and production laboratories.

The guide then delves into a full-cycle scenario of SAP PP-PI, providing practical examples of creating material masters, bills of material, resources, master recipes, production versions, material allocation, standard costing, planned independent requirements, and running MRP. It also explains the process of updating stocks of raw materials, converting planned orders to process orders, checking material availability, releasing orders, issuing goods, confirming orders, receiving goods, calculating variances, doing settlements, and completing TECO.

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Batch Management in SAP: Basic Overview Guide

This document provides a simple overview of batch management within the context of material production and stock management in SAP.

A batch is defined as a subset of the total quantity of a material held in stock, representing a homogeneous unit with unique specifications. Batch Management indicator can be set manually or automatically in the material master record, and it is maintained at different levels – plant, material, and client.

The document highlights the reasons for implementing batch management, such as traceability in case of complaints and recall issues, search via expiration date, ISO certification, and the management of batch characteristics to determine which batch fits a specific requirement.

The guide also provides practical examples of creating weekly requirements, running MRP against those requirements, converting purchase requisitions to purchase orders for raw materials, and creating batch numbers during goods receipt. It further discusses the process of issuing multiple batches to a single production order, a process known as batch splitting.

Finally, the document explains how to use MB56 transaction code to trace the usage of a particular batch of raw material, providing a valuable tool for quality control and customer complaint handling.

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SAP S/4HANA PP Baseline Configuration Guide

Starting with a one page description to the terms of SAP Configuration, SAP Implementation Methodology, and SAP Landscape, this document then provides the 8 steps of baseline configuration of SAP S/4HANA Production Planning (PP) module.

The configuration steps covered in this guide are as follows:

  1. Factory Calendar: This involves creating company-specific dates such as alternate working Saturdays and holidays. The calendar ID can be used in the work center master data for calculating capacities.
  2. Shift and Shift Sequences: This step involves defining the timings for each shift and the sequence of each shift. The grouping created here can be used in the Capacities tab in the work center.
  3. Person Responsible: This refers to the person or group of people responsible for maintaining the master data in certain work centers. This key will now be available to select in the work center.
  4. Capacity Planner Group: This is a person or group of people responsible for planning certain capacities. This key will now be available to select in the capacities tab in the work center.
  5. Work Center Parameter: These are used in formulas for capacity planning, scheduling, costing, PRT management, and determining standard values using CAPP.
  6. Work Center Formula: This involves creating new formulas based on parameters defined in the previous step. The formula is used for capacity planning, scheduling, costing, etc.
  7. Standard Value Key: This key determines the meaning of the six standard values in the operation. It is used in formulas for the calculation of execution time, capacity requirements, and costs.
  8. Control Key: This specifies how an operation or a sub-operation is processed in functions such as orders, costing, or capacity planning. The control key specifies how the business functions you want to carry out with an operation and how the SAP System processes an operation.

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MRP in SAP: Differences Between ECC and S/4HANA

In this document, the author compares the differences between SAP ECC and S/4HANA in terms of Materials Requirement Planning (MRP). Here’s a summary of the key points from the document:

  1. MRP Run: S/4HANA uses MRP Live, which offers improved performance and shorter planning cycles. It also supports more detailed planning scopes and allows for more frequent planning runs, providing more up-to-date supply and demand information.
  2. Demand Driven MRP (DDMRP): This feature is not available in ECC. DDMRP is a pull methodology to plan inventories and materials based on current demand, offering a new way of managing the supply chain.
  3. Predictive Material & Resource Planning (pMRP): This feature is not available in ECC. pMRP in S/4HANA helps identify potential capacity issues and evaluate possible solutions based on a simplified requirements plan.
  4. Production Version Selection: In ECC, there are multiple selection methods available. However, S/4HANA considers the production version with the latest “valid from date”, irrespective of the selection method and lot size.
  5. Batch Management: The transaction codes for batch management have changed in S/4HANA.
  6. Advanced Planning: In ECC, advanced planning requires a separate system and data transfer. In S/4HANA, advanced planning is part of the system, eliminating the need for a separate system and data transfer.
  7. Production Scheduling Board: This feature is not available in ECC. In S/4HANA, the Production Scheduling Board allows for detailed planning of resource schedules and order dates and times.
  8. Material Scrap and Operation Scrap: S/4HANA offers analytical apps that compare actual scrap figures with expected scrap, allowing for feedback loops for updating expected scrap percentages.
  9. Planning File Table: The original planning files in ECC no longer exist in S/4HANA. They have been replaced by the new planning file PPH_DBVM.
  10. FIORI Application Type: S/4HANA offers new FIORI applications for transactional tasks, analytical overviews for KPI analysis, and factsheets for viewing essential information about an object.

The document also provides detailed comparisons of various other features and functionalities, including DDMRP, pMRP, selection methods for production versions, production version status, mass processing, and more. It also highlights the new processes and changes in transaction codes in S/4HANA.

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SAP PP-MRP Configuration Guide

Specialized for a chemical company, this document serves as a reference of SAP PP Step by Step Configuration Guide with screenshots. It covers the configuration steps for Material Requirements Planning (MRP) listed below;

  • Activating SAP’s Material Requirements Planning (MRP)
  • Plant Level configuration for MRP
    • Maintain Environment: Number Ranges
    • Maintain Environment: Check Rule-Backorders
    • Maintain Master Data: MRP Controllers
    • Maintain Master Data: Floats
    • Maintain Planned Orders: Conversion
    • Maintain Planned Orders: Dependent Requirement Availability
    • Maintain Planning Run: BOM/Routing Selection
  • Carry Out Overall Maintenance of MRP Groups

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SAP PP Configuration Guide to BOM, Resources and Master Recipes

Specialized for a chemical company, this document serves as a reference of SAP PP Step by Step Configuration Guide with screenshots. It covers the configuration steps for BOM (Bill of Material), Resources (Work Centers), and Master Recipe.

  • BOM – Bill of Material
    • Define BOM Usage
    • Define Default Values for item status
    • Define Allowed Material type for BOM Header
    • Define BOM Status
    • Define Item Category
    • Define Allowed Material Types for BOM Items
    • Define Explosion Types
    • Define Order of Priority for BOM Usages
    • Define Applications
    • Define Alternative Determination for Multiple BOMs
    • Alternative Determination in Related Application Area
    • Define User-Specific Setting
  • Resource
    • Define Resource Category (Work Center Category)
    • Define Field Selection
    • Define Task List Usage
    • Define Parameters
    • Define Standard Value Key
    • Define Formulas for Resources (Work Centers)
    • Define Person Responsible
    • Define Control Keys
    • Define Capacity Category
    • Define Capacity Planner
    • Define Shift Sequence
    • Define Factory calendar
    • Define Screen Sequence for Resources (Work Centers)
  • Master Recipe
    • Define Profiles with Default Values
    • Assign Material Types

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Mastering Bill of Materials Process in SAP PP: Users Guide

The production master data consists of work centers, routings, Bill of Material and production versions. The Bill of Material data specific to production and planning will be described in the bills of material process definition document. In this document the process of creating and changing a manufacturing Bill of Material in SAP ERP is described.
Bill of materials (BOM) is a hierarchical list of components needed to complete a saleable end-item. BOMs are hierarchical in nature with the top level representing the sub-assembly or end-item. The BOMs that describe the sub-assemblies are referred to as Modular BOMs. A bill of material can define products as they are designed (Engineering Bill of Material), as they are ordered (Sales BOM), as they are built (Manufacturing BOM), or as they are maintained (Service BOM).
After reading this document, you will learn how to:

  • Create/Change/Display Bill of material in SAP (CSO1)
  • Display Multi Level BOM (CS12)
  • Display Multiple BOM (CS14)
  • Display a particular component of BOM(CS15)
  • Mass Change BOM (CS20)

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