Make-to-Stock Production – Discrete Industry SAP Best Practices Purpose, Benefits, and Key Process Steps Purpose This scenario describes a business process, which is typical for companies with lot-size oriented production. The production scenario produces a finished good and all dependent components in maketo-stock production (MTS). Furthermore, the scenario is supported by the main cost object controlling functions required, such as preliminary costing and period-end closing. Benefits Production triggered by a production plan Serial number and batch management included Optional with: quality management, consigned inventory, external processing Key Process Steps Creating Planned Independent Requirements Material Requirements Planning at Plant Level In-House Production (subassembly) In-House final assembly (Finished Good) Capacity Leveling Confirming Assembly Activities © 2013 SAP AG. All rights reserved. 2 Required SAP Applications and Company Roles Required SAP Applications Enhancement package 6 for SAP ERP 6.0 Company Roles Production Planner Production Supervisor Shop Floor Specialist Warehouse Clerk Strategic Planner Engineering Specialist © 2013 SAP AG. All rights reserved. 3 Detailed Process Description Make-to-Stock Production – Discrete Industry This scenario describes a business process, which is typical for companies with lot size oriented production. The production scenarios consist of both goods movements (goods issues and receipts) and confirmation of completion of the production order. Furthermore, the scenario is supported by the main cost object controlling functions required, such as preliminary costing and period-end closing. The typical planning process starts with sales quantity planning. The previous period’s actual sales figures can be used as a basis for future planning. In Sales and Operations Planning, you ensure that production stays in line with sales so that you may create the production plan synchronously to sales. The planning data is transferred from Sales and Operations Planning to Demand Management. Demand Management generates independent requirements, which are used in the subsequent Material Requirements Planning (MRP) run. In material requirements planning, the bill of materials (BOM) for the top-level material demand gets exploded and production is planned right down to procured component level. MRP results in planned orders being generated for the material to be produced. If insufficient warehouse stock is available, purchase requisitions are created for the raw materials required. When the order is created, target costs are calculated for the order lot size (preliminary costing). During the production process, costs incurred are updated on the order, which enables you to keep track of and compare target costs and actual costs at any time. Period-end-closing activities are applied to the order. This includes Work In Progress calculation and variance calculation. After this, Work in Progress is settled to financial accounting and production variances are settled to management and financial accounting. © 2013 SAP AG. All rights reserved. 4 Process Flow Diagram Production Planner Strategic Event Planner Make-to-Stock Production – Discrete Industry Beginning of Planning Cycle Creating Planned Independent Requirements Periodic Plan Revision Logistics Planning (144) Material Requirements Planning at Plant Level & Evaluation of Stock / Requirement List Update Capacity No Capacit y Levelin g O.k.? 1 Yes MRP List Purchase Requisiti on Planned Orders Convert Planned Order to Production Order Material Availabl e? Yes Capacity Leveling Release Production Order Order Print Pick List Confirming Assembly Activities / Final Confirmation Inventory Consumption @ Standard. Cost Warehouse Clerk Manufacturing No Material Staging for Planned Orders Semi-Finished Goods Receipt Goods Issue/ Back flush Goods Receipt Slip Goods Receipt Slip Finished Goods Receipt Period End Closing “General” Plant (181) Plant Contr oller Buyer Inventory @ Standard. Cost Procurement w/o QM (130) © 2013 SAP AG. All rights reserved. Procurement of Stock Material with QM (127) Procurement & Consumption of Cosigned Inventory (139) MM Subcontracti ng (138) PPSubcontracti ng (External Processing) (150) 5 Process Flow Diagram Production Supervisor Event Make-to-Stock Production – Discrete Industry 1 © 2013 SAP AG. All rights reserved. Review Operation List 6 Legend <Function> Symbol Description Usage Comments Band: Identifies a user role, such as Accounts Payable Clerk or Sales Representative. This band can also identify an organization unit or group, rather than a specific role. Role band contains tasks common to that role. Symbol Diagram Connection The other process flow symbols in this table go into these rows. You have as many rows as required to cover all of the roles in the scenario. External to SAP External Events: Contains events that start or end the scenario, or influence the course of events in the scenario. Business Activity / Event SubProcess Reference Process Decision Flow line (solid): Line indicates the normal sequence of steps and direction of flow in the scenario. Flow line (dashed): Line indicates flow to infrequently-used or conditional tasks in a scenario. Line can also lead to documents involved in the process flow. Connects two tasks in a scenario process or a non-step event Business Activity / Event: Identifies an action that either leads into or out of the scenario, or an outside Process that happens during the scenario Does not correspond to a task step in the document Unit Process: Identifies a task that is covered in a step-by-step manner in the scenario Corresponds to a task step in the document To next / From last Diagram: Leads to the next / previous page of the Diagram Flow chart continues on the next / previous page Hardcopy / Document: Identifies a printed document, report, or form Does not correspond to a task step in a document; instead, it is used to reflect a document generated by a task step; this shape does not have any outgoing flow lines Financial Actuals: Indicates a financial posting document Does not correspond to a task step in a document; instead, it is used to reflect a document generated by a task step; this shape does not have any outgoing flow lines Budget Planning: Indicates a budget planning document Does not correspond to a task step in a document; instead, it is used to reflect a document generated by a task step; this shape does not have any outgoing flow lines Manual Process: Covers a task that is manually done Does not generally correspond to a task step in a document; instead, it is used to reflect a task that is manually performed, such as unloading a truck in the warehouse, which affects the process flow. Existing Version / Data: This block covers data that feeds in from an external process Does not generally correspond to a task step in a document; instead, this shape reflects data coming from an external source; this step does not have any incoming flow lines System Pass / Fail Decision: This block covers an automatic decision made by the software Does not generally correspond to a task step in the document; instead it is used to reflect an automatic decision by the system that is made after a step has been executed. Financial Actuals Process Reference: If the scenario references another scenario in total, put the scenario number and name here. Corresponds to a task step in the document Sub-Process Reference: If the scenario references another scenario in part, put the scenario number, name, and the step numbers from that scenario here Corresponds to a task step in the document Process Decision: Identifies a decision / branching point, signifying a choice to be made by the end user. Lines represent different choices emerging from different parts of the diamond. Does not usually correspond to a task step in the document; Reflects a choice to be made after step execution © 2013 SAP AG. All rights reserved. Usage Comments Hardcopy / Document Budget Planning Unit Process Process Reference Description Manual Process Existing Version / Data System Pass/Fail Decision 7 Materials Requirement Planning - MRP Material Reqmts Planning Planned Ind. Requirements Dependent Reqmts Reservations Planned Order Convert Production Order Warehouse © 2013 SAP AG. All rights reserved. 8 Alternative Planning Strategies for Finished Product Strategy Customer requirements passed on to production This means . . . Net Requirements Planning (10) No Planning with Final Assembly (40) Yes ... sales orders do not influence production ... sales orders that exceed planned independent requirements can influence production ... the main objective is to ensure smooth production ... the most important factor here is the ability to react flexibly to customer demand Planned independent requirements allocated and reduced during sales order processing No Yes Planned independent requirements reduced at goods issue for delivery Yes No © 2013 SAP AG. All rights reserved. 9 Work Center Work Center: Assembly Default values Routings Routings Costing Data Sched. Data Capacity Data Costing Scheduling & Capacity 1010,2150,3160,- © 2013 SAP AG. All rights reserved. 10 Routing Work Center / Operation Routing Header Operation 10: Final Assembly Work center Control key Standard values Activity types Description .... Material Components © 2013 SAP AG. All rights reserved. 11 Planned Order Conversion Production order Planned orders Individual Conversion Individual Conversion Planned orders Production orders Collective Conversion Collective Conversion © 2013 SAP AG. All rights reserved. 12 Production Order Creation Friday January 28 2011 Manually Tuesday July 12 2011 Requirements planning Automatically Specify order type Define order item Copy routing Lead time scheduling Copy bill of material Availability check Optional changes Optional (Customizing) © 2013 SAP AG. All rights reserved. Save production order 13 Production Order Processing Order settlement Order header Production Order Order proposal (planned order) Operations Order creation Goods receipt Components Availability check Confirmations Material withdrawal © 2013 SAP AG. All rights reserved. Costs 100 20 50 Order release and batch determination for components 14 Goods Movement Prod. order Warehouse Operation Mat. comp. Material Costs Goods movement Accounting document Material document © 2013 SAP AG. All rights reserved. Update of stock quantities Update of stock values materials can be batch controlled 15 Goods Issue Goods issue posting Material document © 2013 SAP AG. All rights reserved. Acctg. document Updating stock quantities Updating stock values Reducing reservations Calculating actual costs and updating the order 16 Production Order Confirmations Manual entry Operation 0010 Operation 0020 Operation 0030 Order confirmation . . . Operation . . . . Production order © 2013 SAP AG. All rights reserved. 17 Production Order - Preliminary Costing Planned costs Material components l l Ind. "Rel. to costing" Price Phases Cost elements: elements: l Material costs l l Costs for external procurement Order type / Plant l Production costs Costing variant Display planned/actual costs l l l Cost elements Cost itemization Cost component split © 2013 SAP AG. All rights reserved. l l Production overhead costs Costs for external processing Control key “costing indicator” Resources l Material overhead costs Gen. operation values Standard values l Formula key for costing Cost center Activity type Formula constants Cost calculation log 18 Cost of Production Order Material components - Quantities - Prices Operation Work center - Work center - Standard value - Quantities - Cost center - Activity types - Formulas Cost center - Activity types Activity cost - Periods Material costs Internal activities costs Overhead calculations Production order cost © 2013 SAP AG. All rights reserved. 19 WIP and Variance Calculation in Lot-Based Cost Object Controlling Actual Costs Actual Costs = WIP at Actual Costs Actual Costs - - Delivery Value Delivery Value = = WIP at Actual Costs Variances Order Status Pre-Released or Released © 2013 SAP AG. All rights reserved. Partially Delivered Finally Delivered or Technically Completed 20 Settlement of Order (Example) Product cost planning Lotsize 1 PC Production Order Mat. F126 COPC Material 600 Production Surcharge 300 1100 Material Master Standard Price = 2000 2000 © 2013 SAP AG. All rights reserved. Actual Cost Material Production Surcharge 800 1.200 400 2.400 -2.000 GR Target Version 0 Price Qty Structure Scrap Lotsize 150 150 100 0 0 400 Variances Financial Accounting Warehouse COPC FI Settlement COPA Price difference 400 21 © 2013 SAP AG. All rights reserved. No part of this publication may be reproduced or transmitted in any form or for any purpose without the express permission of SAP AG. The information contained herein may be changed without prior notice. Some software products marketed by SAP AG and its distributors contain proprietary software components of other software vendors. National product specifications may vary. These materials are provided by SAP AG and its affiliated companies ("SAP Group") for informational purposes only, without representation or warranty of any kind, and SAP Group shall not be liable for errors or omissions with respect to the materials. The only warranties for SAP 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. SAP and other SAP products and services mentioned herein as well as their respective logos are trademarks or registered trademarks of SAP AG in Germany and other countries. Please see http://www.sap.com/corporate-en/legal/copyright/index.epx#trademark for additional trademark information and notices. © 2013 SAP AG. All rights reserved. 22
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