6. Metodología
6.2. Cuadro resumen de objetivos, actividades, herramientas y población (o muestra)
Business Example
You release your order for material T-FI1## and generate the control recipe for the order at the same time.
Initiate Production by Releasing an Order
Now that you have planned the production of your ice cream, you will need to release the orders to the production departments in order initiate manufacturing.
1. Release your process order for the production of the material T-FI1## in Plant 1100 in collective processing. At the same time generate the control recipe for the order. Create the process order using order type PI01.
2. Display one of your process orders for T-FI1## at plant 1100, now that it has been released and the control recipe has been generated. What is the process order number?
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3. Which activities were performed when the order was released?
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4. Review the Goods Receipt tab. Was a batch created?
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5. Review the Components. Do the components have batch numbers assigned? Hint: Select the Materials button.
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Unit 2 Solution 6
Release a Process Order
Business Example
You release your order for material T-FI1## and generate the control recipe for the order at the same time.
Initiate Production by Releasing an Order
Now that you have planned the production of your ice cream, you will need to release the orders to the production departments in order initiate manufacturing.
1. Release your process order for the production of the material T-FI1## in Plant 1100 in collective processing. At the same time generate the control recipe for the order. Create the process order using order type PI01.
a) SAP ECC menu path: Logistics → Production - Process → Process Order → Process Order → Release (COR5)
The Release Process Order: List screen appears.
b) Enter order type PI01
c) Enter your plant 1100 and material T-FI1##
d) Delete the entries in the fields for MRP controller and date selection.
e) Select Execute Selections (F8) icon.
f) Choose Select All .
g) Choose the Control Recipe icon at the bottom of the screen.
h) After you have released the order and created the control recipe, select Back (F3) to exit the list.
2. Display one of your process orders for T-FI1## at plant 1100, now that it has been released and the control recipe has been generated. What is the process order number?
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a) SAP ECC menu path: Logistics → Production - Process → Process Order → Process Order → Display (COR3)
b) The process order number varies.
3. Which activities were performed when the order was released?
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a) Look at the order status. Note, in particular, the statuses REL - Order Released, CRCR - Control Recipe Created, BCRQ - Order to be handled in batches, BASC - Batch
Assignment Complete, and MACM - Material Committed.
4. Review the Goods Receipt tab. Was a batch created?
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a) A batch number was created. The number varies.
5. Review the Components. Do the components have batch numbers assigned? Hint: Select the Materials button.
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a) Yes. Batch determination was automatically executed for material components managed in batches during order release. Choose the Back button to leave the transaction.
Lesson: Executing Process Orders
HTML-Based PI Sheet
The SAP PI sheet favors processing on the screen, which means the process operator is to enter, confirm, or complete data interactively.
Figure 27: HTML-based PI Sheet I
PI sheets are created in HTML layout. The browser-based PI sheet gives you the advantage of a flexible, user-specific layout definition and allows you to define frames, for example, for including documents, graphics, Internet and Intranet links.
Figure 28: HTML-based PI Sheet II Unit 2: Production with Process Orders
● Display of information about the process (control instructions, for example)
● Input fields and tables for reporting process data, input validations and signatures
● Batch determination and batch check
● Process data calculation
● Reading and writing data from internal or external applications
● Link to quality management results recording
● Sequence definition for determining the processing sequence of phases
● Comments on documentation and messages from process events The Material Staging Process
To organize the material staging, the SAP ECC and SAP SCM systems provide the following different procedures that depend on the type of inventory management and warehousing:
1. Warehouse management with the MM-IM (Inventory Management) component 2. Replenishment control with the Kanban component
3. Storage bin management and replenishment control with a warehouse management system based on the component LE-WM (Logistics Execution Warehouse Management in SAP ECC) or EWM (Extended Warehouse Management in SAP SCM).
Figure 29: The Material Staging Process
The basis for material withdrawal for process orders are the following applications:
● Material withdrawal slips
● Pull lists
● Pick lists
● PI sheets
Lesson: Executing Process Orders
● Weighing systems linked via the PI-PCS interface (or similar documents or techniques) For the material staging from a warehouse management system, there are different options for the process order:
● Pick parts:
Pick parts are provided for the process order in exactly the same quantity as the requirements quantity. The staging of these parts for the process order may occur in a physical storage bin or a dynamic storage bin.
● Crate parts:
Crate parts are ordered manually when a crate is almost empty.
● Release order parts:
Release order parts are ordered manually. The required quantity is calculated using the target quantities of the components in the selected released orders.
Standard Postings for Process Orders
The standard postings for process orders (goods issue, confirmation, goods receipt) can be entered manually in the SAP ECC system, or using process messages from a PI sheet or a process control system.
Figure 30: Standard Postings for Process Orders
The process instructions of the order define which process messages are requested from a PI sheet or a process control system.
Unit 2: Production with Process Orders
Figure 31: Process Order: Goods Issue Posting
The following functions are executed when a goods issue is posted:
● Storage location-related update of stock and consumption fields
● Reduction of reservations (for planned withdrawal)
● Determination of actual costs (evaluation) and update of order
● Generation of material documents, accounting documents and cost accounting documents
The following documents are created:
● The material document describes the goods movement from the materials management (stock) point of view.
● The accounting document describes the goods movement from the financial accounting point of view.
● The cost accounting documents are used for various cost analysis purposes.
In this context you have the following options:
● When you display the material document, you can branch to the other documents.
● You can print a goods issue document.
Confirmations
Confirmations are an important basis for entering internal activities performed for the order, for the progress check and subsequent capacity requirements planning. For this reason, exact real-time confirmations are of particular importance. A confirmation causes various additional functions to be executed.
Lesson: Executing Process Orders
Figure 32: Confirmations – Overview
Confirmations are always executed in the SAP ECC component, but can be implemented with different technical procedures:
● Using online transactions
● Using the browser-based Enterprise Portal
● Using the PP-PDC interface
● Using automatic process messages
● Using an SAP MII server
There are various procedures for confirmations. Each procedure implements different requirements that a company might have. Depending on the application, one or more procedures may be used. The procedures must be selected to suit the methods of organization within your company and the allowed workload.
Unit 2: Production with Process Orders
Figure 33: Types of Confirmations
Each confirmation is entered with a status:
● Partial confirmation
● Final confirmation
● Automatic final confirmation
For the most part, the main types are the following:
● Phase-related confirmations:
A phase confirmation allows you to confirm an order step by step.
● Secondary resource-related confirmations:
A secondary resource can be compared to a suboperation and can be confirmed separately.
● Order-related confirmations:
Order confirmation is a confirmation of the entire order at order header level.
Note:
You can carry out a confirmation for an order only if no confirmations have already been entered for the phases.
Flexible Data Entry with Process Messages
Process messages are data structures with which actual data for a process is confirmed from process control to one or more destinations.
Lesson: Executing Process Orders
Figure 34: Flexible Data Entry with Process Messages
The SAP standard system contains a number of predefined message categories that enable you to transfer actual data from process control to the SAP ECC system.
Note:
You can define your own process messages in customizing according to your own specific requirements.
Production in Compliance with GMP
The functions for GMP-compliant production (GMP = Good Manufacturing Practice) fulfill special requirements from the pharmaceuticals industry (safe production, product liability, obligation to produce supporting documents).
Figure 35: Functions for production in compliance with GMP Unit 2: Production with Process Orders
standard in many areas of process industries. In particular, they must be taken into account in processes of the pharmaceutical industry.
Figure 36: Production in Compliance with GMP
● Options for GMP-compliant production:
- You can specify that a process order can only be created if an approved recipe exists.
The order data is therefore locked and cannot be changed. The approval procedure is performed in SAP ECC Engineering Change Management.
- You can exchange information about the product quality and analysis values between the production plant and the laboratory or the quality assurance system. You use the SAP ECC quality management functionality to do so.
- You can use the inspection results for batch specification by automatically copying them to the characteristics of the batch produced.
- You can activate the digital signature function to execute certain business operations in the SAP ECC system.
● Tools for GMP-compliant production:
- Material identification function:
You use the material identification function to check whether the material that was picked for the process order is completely available at the production line and will be used in the correct sequence.
- Material reconciliation function:
You use the material reconciliation function to analyze and verify the ingredients and yield at the end of the production process.
- Batch record:
With regard to product liability, the batch record contains all planned and actual data for the production process of a batch.
Lesson: Executing Process Orders
Unit 2: Production with Process Orders