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Make-to-Stock Production – Process Industry SAP Best Practices Baseline Package SAP Best Practices.

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Präsentation zum Thema: "Make-to-Stock Production – Process Industry SAP Best Practices Baseline Package SAP Best Practices."—  Präsentation transkript:

1 Make-to-Stock Production – Process Industry SAP Best Practices Baseline Package SAP Best Practices

2 Scenario Overview – 1 Purpose This scenario provides an integrated platform for batch-oriented process manufacturing. This supports processes in the following manufacturing industries, chemical, pharmaceutical, food and beverage industries as well as the batch-oriented electronics industry. The Sales and Operation Planning process results in independent requirements which are used in material requirement planning (MRP). Planned orders are converted to process orders for manufacturing execution. Material provisioning to the shop floor follows a similar process to that of repetitive manufacturing leveraging the pull list and automatic goods issues and goods receipts at time of order confirmation. Customer orders decrease the planned independent requirements at time of order entry and cost of sales is recognized in profitability at time of invoicing. Benefits Recipe-oriented production Materials handled in batches according to a recipe specified for the appropriate production quantity Cost Object Controlling Key process flows covered Planned Independent Requirements Creation Material Requirements Planning (MRP) Make-to-stock production for semi-finished and finished products Purpose and Benefits:

3 Scenario Overview – 2 Required SAP enhancement package 4 for SAP ERP 6.0 Company roles involved in process flows Production Planner Production Supervisor Warehouse Clerk Shop Floor Specialist SAP Applications Required:

4 Scenario Overview – 3 Make-to-Stock Production – Process Industry Sales-order-independent production using MTS (Make-to-stock) production / process order processing MRP planning with planned independent requirements gives planned orders for production as well as purchase requisitions for raw materials Planned orders are converted into process orders Components are staged to the shop floor location Batch-management components are issued at production start immediately, semi-finished and finished products produced, in conjunction with batch management Backflushing is used for the packaging material (without batch management) at finished product confirmation Process order confirmation triggers order controlling and settlement Detailed Process Description:

5 Process Flow Diagram Make-to-Stock Production – Process Industry Shop Floor Specialist Event Plant Control ler Period End Closing General Plant (181) Beginning of Planning Cycle Periodic Plan Revision Material Staging for Planned Orders Confirmation of Production Pick List Custom er Procurement w/o QM (130) Strategic Planner Multilevel Order Report Order List Standard. Cost Post Goods Receipt for Process Order Goods Issue of Batch Managed Components Goods Receipt Slip Shop Floor Specialist / Ware- house Clerk Goods Issue Slip Inventory Std. Cost Goods Issue for Back Flushed Components Production Planner Capacity Evaluation Yes Prod. Superv. Material Requirements Planning at Plant Level & Evaluation of Stock / Requirement List Purchase Requisition MRP List Check Material Availability Change Order Schedule Planned Orders Material at Shopfloor Location? Capacity Leveling OK? Create Planned Independent Requirements No Convert Planned Order to Process Order Logistics Planning (144) Yes No

6 Legend SymbolDescriptionUsage 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. 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. Role band contains tasks common to that role. External Events: Contains events that start or end the scenario, or influence the course of events in the scenario. 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 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 SymbolDescriptionUsage Comments 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. External to SAP Business Activity / Event Unit Process Process Reference Sub- Process Reference Proces s Decisio n Diagram Connection Hardcopy / Document Financial Actuals Budget Planning Manual Proces s Existing Version / Data System Pass/F ail Decisio n

7 Appendix Master Data Used - Product Structure F29 Finished Good MTS PI (FERT-PD) B Batch Management B Bulk Material S24 Semifinished Good, Liquid (HALB-PD) B FIFO Exp. date LQ Lean QM R15 RAW Material (ROH - PD) R09 RAW Material (ROH - PD) R19 RAW Material (ROH - PD) LQ R30 RAW Material, Reorder Point (ROH - VB) B FIFO Master Recipe MR-50002/1 - Packing Master Recipe MR-50001/1 – Mixing / Bottling BB FIFO

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