production execution - erpdb
TRANSCRIPT
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PRODUCTION EXECUTION
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Module 1: Production Planning Overview
Module 2: Master Data
Module 3: Production Execution Process
Module 4: Process Manufacturing
Course Map
Module 5: Summary
Table of contents
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What is Production Planning?
Production Planning is the process of aligning forecasts with manufacturing capability to create production and procurement schedules for finished products and component materials.
It also tracks and records the detail of the manufacturing process, for example, the planned and actual costs and material flows
It is fully integrated with the other SAP modules: SD, MM, LE, QM, CO
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PP flow & Integration
Sales & Ops Planning MRP
Capacity Req.Planning
Long TermCapacity Planning
Demand Management
Production Execution
CO(Cost
Control)
MM – LE(Stock
Control)
QM(QualityControl)
FI /CO MM
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Course Objectives
Understand the principles of Production ExecutionDefine the material staging processDescribe how to confirm operations in ordersExplain now to back flush componentsDescribe how to deal with failed backflushes and make manual correctionsPerform Production Execution transactions
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Module 1: Production Planning Overview
Module 2: Master Data
Module 3: Production Execution Process
Module 4: Process Manufacturing
Course Map
Module 5: Summary
Table of contents
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Master Data Related Transactions
Practice the following transactions
MM03 – Display Material MasterC203 – Display Master RecipeCRC3 – Display ResourceCR03 – Display Work Center
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Module 1: Production Planning Overview
Module 2: Master Data
Module 3: Production Execution Process
Module 4: Process Manufacturing
Course Map
Module 5: Summary
Table of contents
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What is Production Execution?
Production Execution is the final part of the Production Planning processThe availability of materials for production is checked in the production location. The transfer of any shortages is requested using the staging transaction.As orders are completed, order operations are confirmed. Material and utility usage is recorded by ‘back-flush’
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6Production
Activity
Production Planning Processes
Sales & Operation Planning
1
5Capacity
RequirementsPlanning
Long TermPlanning
23
Demand Management
4 Materials Requirements
Planning
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Production Execution Process Flow
PRODUCTION
EXECUTION
PLANNING
PRODUCT
INPUTS
PROCESS
OUTPUTS
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Production Execution ProcessView planned
orders
Create batch( if required)
Make product with Production Order
Record consumption & output
Deal with goods issue, confirmation & transaction errors
Adjust theoretical yield & consumption to actual
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Production orderA production order defines which material is to be processed, at which location, at what time and how much work is required. It also defines which resources are to be used and how the order costs are to be settled.
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Order Status
Created – Order is created and changes can be madeReleased – Order released, suggested not to make any changePartially confirmed – Production qty/activity partially confirmedFully confirmed – Production qty/activity fully confirmedDelivery completed – Entire order quantity has been received Technically completed – Order processing is over, ready for month end processing by accounts
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Confirmation of Production Orders
Confirmation for operation – Reporting of yield quantity and consumed activities and utilities for specific order and at specific operation. Milestone confirmation – Reporting of yield quantity and consumed activities and utilities for a specific order and specific operation. This confirms of all the previous operations in the order. Collective confirmation - Reporting of yield quantity and consumed activities and utilities for many orders.
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Manufacturing Month End Process
WIP calculationWork in progress are the items which are issued from the stores and the process is not completed and lying in the shop floor. WIP is calculated by costing and reported in the inventory value.
Variance calculationVariance is the difference between planned and actual consumption of material, activity and utilities. It is calculated at the end of the month.
Settlement of orderCalculated variance for each order are settled to the costing objects according to the costing methodology and procedures.
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Demonstration and Exercises
Practice the following transactions
MMBE – Stock overviewMD16 – Display planned ordersMD04 – Stock requirement list and convert planned order to production orderMIGO – Goods issue to production orderMIGO – Goods receipt for production orderCO15 – Confirmation for order
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Who is Responsible for Production Execution?
Plant Operations
Responsible for the detailed control of manufacturing orders, including material staging, printing of any shop floor documents and recording of produced quantities. These quantities will also cause the issue of the appropriate quantities of raw materials and components via backflushing
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Module 1: Production Planning Overview
Module 2: Master Data
Module 3: Production Execution Process
Module 4: Process Manufacturing
Course Map
Module 5: Summary
Table of contents
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Process manufacturing
Process manufacturing is used in processing areas as it gives greater control over very complex processes
Process manufacturing allows the end user to input very specific information across multi steps easily.
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Process - Manufacturing Procedures
View Orders
Record consumption & output
Record process data & batch characteristics
Final Confirmation & Back Flush
Make product
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Confirmation – Production / Process Orders
Partial confirmationFinal confirmationPartial confirmationFinal confirmation
Confirmation statusConfirmation status
Order headerOrder header
OperationsOperations
ComponentsComponents
Costs MaterialLabor...
Costs MaterialMachineUtility
2050
100
Output goods receipt
Determine actual costs
Confirmation functions
Backflush components
Backflush utilities
Reduce capacity requirements
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Transactions
Practice the following Transactions
MMBE – Stock OverviewCOID – Display Process OrderMSC1N – Create BatchCORK – Process order confirmation
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Transactions
Practice the following Transactions
COR2 – Process Order changeCORS – Cancel Process OrderCOIO – Process Order ReportMCRV – Process OrderMCRE – Material UsageKKBC-HOE – Product Cost analysis
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Repetitive manufacturing
Repetitive manufacturing is used for materials that are produced in a repetitive environment, where the process is ongoing
Repetitive manufacturing is very flexible in its application and is an excellent tool for repetitive processes
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Repetitive manufacturing Procedures
View planned orders
Make product
Record consumption & output
Create batch ( if required)
Deal with Back Flush & transaction errors
Adjust theoretical yield & consumption to actual
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Rep.Mfg.Related Transactions
Practice the following Transactions
MMBE – Stock OverviewMF51 – Production list reportMSC1N – Create BatchMFBF – Back Flushes
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Report Related Transactions
Practice the following Transactions
COGI – Post processing componentsMF41 – Month-End CorrectionsMCRE – Material UsageMCP6 – Goods ReceiptKKBC-HOE – Product Cost analysis