SAP PPPI Process Order Creation

Creation of Process order The process orders in SAP PPPI are very much similar to production orders in SAP PP. The only difference which is visibly seen is the play of the master recipe in process orders bringing in concepts such as material quantity calculations, process instructions. When the process order is released, the system allows the creation of the control recipe for the bundling up the process instruction categories for a given control recipe destination. You can configure the point of creation of the control recipe i.e., at orders creation or at order release using the production scheduler profile (transaction code CORY). The below screen shot for the production scheduler profile is a cropped image which only shows the automatic action section which is worth mentioning for SAP PPPI.

Figure 48

Contribution of the Settings done in Order Type Dependent Parameter for Process Order It would also be worth mentioning the configuration involved in order type dependent parameters required for creation of the process order. Here we would only be looking at settings especially available for configuration in SAP Process industry vis--vis what we have in SAP production planning. The below screen shot shows the evident different (as seen in the first tab of the order type dependent parameters settings); rest of the tabs are pretty much same and are already explained the SAP PP Production planning for discrete manufacturing section. The transaction code COR4 is used to configure the order type dependent parameter for SAP process industry manufacturing. a) Options for selection of automatic and manual selection of the production versions are seen on the screen. b) Checking component details along with checking of the operation details is another option available. The checking of the component details when it is brought in to the process order is possible.

c) Release of the orders after an approval is granted is an option available in SAP PPPI. This can be configured for the order through the selection of the indicator Approval required. d) Master recipe selection process can be also be configured, whether the selection is optional or mandatory and whether it is automatic or manual. e) One can also set the perspective in which the phase relationships should be displayed, i.e., whether as predecessor or successor or both mixed or as created in the order. In other words, when you go route yourself into phase relationship in a process order, you can set an option to display a successor to a phase that you have chosen or to display a predecessor to a phase that you have chosen or whether you want to display both successor & predecessor to the phase that you have selected (the mixed option). Lets say that you have selected phase 10, 20 and 30 and pressed the phase relationship option to view their relationship and if you have chosen the predecessor option here, then for phase 10, it will not show any predecessor phase, but for phase 20, it will show phase 10 as predecessor and for phase 30, it will show 20 as the predecessor phase.

f) The selection ID helps you to select the selection priority list for selection of the master recipe. g) There are 3 settings for the process data documentation specifying whether you want process data documentation or not. This is only used in SAP PPPI. The process data documentation enables you to create a list of quality relevant data and store it in optical archive. You can archive either order data records or batch records. The settings define whether you want to use the order records i.e., it contains all the process related quality relevant data that is collected around a process order or you want to use batch records i.e., it contains all the process related quality relevant data upon the production of a batch. The batch records comply with the guidelines on goods manufacturing practices (GMP) for pharmaceutical and food processing industries. Here the production related information is stored/archived.

Figure 49

Creating a Process Order in SAP PPPI Following are some important transaction codes: a) Creation of Process orders can be done using the transaction code COR1 (Change is COR2, Display is COR3). b) Similarly you can create a process order from the conversion of a planned order using the transaction code COR7 (individual conversion) or COR8 (collective planned order conversion). c) To separately release a process order after its creation, you can use the transaction code COR5. Upon the creation of the process order, the following activities are carried out automatically or manually in SAP PPPI as similar to a large extent to that in SAP PP: a) Pull in the Master Recipe through the use of production versions. The master recipe would bring in the material list, the material quantity calculations associated with the material list.

b) Pull in the Relevant Bill of Material through the use of the production version. One can argue that the BOM is actually brought inside the production order when the master recipe is brought in and that argument is true to a large extent. c) Batch Allocation is carried out automatically or manually in the process order. d) The system executes all the formulas of the material quantity calculations using the batch allocations done in the component overview, thus changing the quantities of the header material and the components. e) One can make the necessary changes to the operation overview of the process order, before the release of the process order, since the release of the process order would create the control recipe. f) The creation of the process order creates a reservation number for the process order, thus reserving all the components for the process order execution. g) The creation of the process order does not create a control recipe nor can you print any shop floor papers. h) If the process order is created from a planned order, the basic dates and the quantities are copied. The production dates are calculated using the basic dates. i) You can change/add/remove process instruction categories which are flown in as a part of the master recipe of the process order. There could be requirements of assigning values manually for some of the process instruction characteristics in some of the process instruction categories assigned to the control recipe destinations of the phase. j) The release of the process order would create the control recipe for every given control recipe destination of the process order (if configured in production scheduling profile). If there are 2 control recipe destinations used in the process order then the system would create 2 control recipes for the process order. k) The release can also carry out scheduling of the process order (if set in the production scheduling profile). The scheduling is carried out depending upon the parameters set in the scheduling parameters for a process order type. The capacity requirements are also generated for the resources if that is configured in the scheduling parameters. l) You can also create a test control recipe in a process order, to check/validate certain things.

m) The scheduling, the capacity allocations procedures, the costing methodology, everything would remain the same as in SAP PP. n) The process order creation process, the release process, the manual confirmation, the material staging, the goods issues, the goods receipts process, i.e., the overall execution process of a process order is exactly same as that of the production order in SAP PP and as spoken earlier in the previous paragraphs, but apart the creation of a control recipe and process management is an exclusive process of SAP PPPI.
SAP PPPI - Process Management Execution in a Process Order

Processing of the Control Recipe The creation of control recipe and the use of control recipe to carry out business functions (carrying out shop floor execution functions) as a substitute to the manual shop floor execution in SAP is a special feature available in SAP PPPI. Following are control recipe statuses, explained:

a) When the control recipe is created, the process order gets the system status CRCR control recipe created. b) When a control recipe is finished and completely executed, the process order gets a system status CRFI. c) When the control recipe is discarded before the start of the execution then process order gets a system status CRAB Control recipe discarded (similarly the processing of the control recipe can be terminated as well, if the work on the control recipe is already started). d) In case of a PI sheet, if you set the PI sheet to Completion Status (when all the entries, calculations are fully completed in the sheet), a process message category named PI_CRST is automatically sent to SAP, this process message category would have a process message characteristics PPPI_CONTROL_RECIPE_STATUS whose value would have been set to processed. The status CRFI is set on the process order. Similarly for setting a completion status on the control recipe, when you are working with an external system, a process message category named PI_CRST has to be sent to SAP with the control recipe status value set as processed thereby setting the status CRFI on the process order. e) In case of a PI sheet, if you set the PI sheet to technical completion (when you want to prematurely stop processing of the PI sheet), a process message category named PI_CRST is automatically sent to SAP,

this process message category would have a process message characteristics PPPI_CONTROL_RECIPE_STATUS whose value would have been set to terminated. The status CRAB Control recipe discarded, is set on the process order. And similarly when you are working with an external system, and want to terminate or discard a control recipe, a process message category named PI_CRST has to be sent to SAP with control recipe status set as terminated.

Downloading of the Control Recipe Control recipe once created needs to be downloaded to the specified control recipe destination/s. To do this, you can download it manually using the control recipe monitor (transaction code CO53) under human supervision or you can schedule a background job for the downloading program RCOCB006 (batch job name SAP_NEW_CONTROL_RECIPE). The control recipe monitor shows the sent control recipes, information on all the executed control recipes and information on all the terminated and discarded control recipes with logs included. The selection criterion is plant and date ranges like any other monitor or report. Once is control recipe is downloaded to the destinations of type 1 and 4, it is called as a PI sheet whereas control recipes downloaded to the destinations of type 2 and 3 reach the external system or external process control system. Below is a Control recipe monitor screen shot that is used to send the control recipe to their respective destinations.

Figure 50

If you are working with PI sheets, then the operator should enter the details for the PI sheet created for a process order using the transaction code CO58 (Display of PI sheet is transaction code CO56 and Deletion of PI sheet is The following are some important transaction code CO59) Once the PI sheet is completed and saved, the detailed entered in the PI sheet as process messages, for enabling execution of various business processes in SAP are to be uploaded and processed in SAP depending upon the type of the process message category. Processing of the Process Messages After processing the control recipe at the destinations, i.e., the destination (an operator or the process control system) provides the values for the process message characteristics of a process message category. The process message category or the process messages is sent back to SAP and subsequently processed in SAP depending upon the type of the process message category. The process messages are sent to the destination by the process management. The messages are first sent to the process management and then transferring the process messages to the destinations i.e., updating the process messages depending upon the type of the process messages. The process message categories or the process messages (as they are called) would be checked for missing values and authenticity.

Process messages which are created for a test are monitored and checked, though they are not processed at the destination as normal process message would. The process messages are uploaded and processed into SAP, either automatically using an upload batch job program name - RCOCB002 (for process messages existing cross plants) or RCOCB004 (for process messages existing at a plant) or done manually through the process management monitor (transaction code CO54).

Figure 51

Process message categories which end up with errors or are terminated during processing can be resubmitted for processing by the use of process management monitor as seen above. SAP also provides an option to create the process message category manually using the transaction code CO57. Here you should enter the plant, the process message category and the values for the process message characteristics which are required or sufficient to process the process message category in SAP. The Process message category can be created for test purpose or for final execution. This process message category like any, would reach the process management monitor from where it has to be updated in SAP. Depending upon the type of the process message category, the process messages are processed in SAP. The following are the process message category types.

 BAPI or Function modules are used to update the process messages in SAP. The process messages once received in SAP are processed using these function modules. You can define your own function modules or you can use the existing standard function modules. Transaction code SE37 can be used to access these function modules. External Functions to coordinate with the external process control system with process messages through RFC connections (a RFC destination should be created for every external system). Transaction code SM59 can be used to define the RFC destinations to communicate with the external system. SAP Office User is a destination type which is used to inform specific SAP users about the status of the control recipe and process messages (in short the status of the production run) The process message characteristics data can be updated in user Defined ABAP tables. One can define the ABAP tables and access them through transaction code SE11. Alerts of critical situation or milestones in the production run, from the external control system or internal shop floor operator using the PI Sheets can be sent to the multiple recipients as SMS or email. You can define Alert categories using SAP transaction code ALRTCATDEF