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Table Of Contents
1. PURPOSE OF THE DOCUMENT............................................................................................................ 5 1.1 2. Purpose ................................................................................................................................................ 5
PRODUCTION PLANNING...................................................................................................................... 6 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.9 2.10 2.11 2.12 2.13 2.14 2.15 2.16 2.17 2.18 2.19 2.20 2.21 2.22 2.23 2.24 2.25 2.26 2.27 2.28 2.29 2.30 2.31 Define MRP Controller........................................................................................................................ 6 MRP Type ............................................................................................................................................ 7 Lot Size................................................................................................................................................. 8 Defining MRP Groups ......................................................................................................................... 9 Defining Special Procurement Type ...................................................................................................10 Define Scope of Planning for Total Planning .....................................................................................11 Scheduling Parameters .......................................................................................................................12 Define Scheduling Margin key ............................................................................................................13 Selection ID for BOM .........................................................................................................................14 Defining BOM Explosion ....................................................................................................................15 Define Number Ranges for Planned Independent Requirements ........................................................16 Define Version Numbers .....................................................................................................................16 Defining Strategy for MRP .................................................................................................................18 Define Strategy Group ........................................................................................................................18 Define Planning Horizon ....................................................................................................................19 Defining Availability of Stock .............................................................................................................20 Defining Rescheduling Check for Plant and MRP Group...................................................................21 Define Number ranges for Planning Run............................................................................................22 Planning File Entry for Termination ..................................................................................................23 Maintain Rounding Profile .................................................................................................................24 Define Storage location MRP per plant..............................................................................................25 Defining Parallel Processing for MRP ...............................................................................................26 Assigning MRP Checking Rule ...........................................................................................................27 BOM Usage.........................................................................................................................................28 Defining Item Categories ....................................................................................................................29 Define Reasons for Variances.............................................................................................................29 Define Number ranges for Manual Processing...................................................................................30 Activating Requirements Planning......................................................................................................31 Defining Item Numbers of Order Types ..............................................................................................32 Defining Conversion Planned Order to Process Order......................................................................33
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PRODUCTION PLANNING FOR PROCESS INDUSTRIES...............................................................35 3.1 3.2 3.3 3.4 Define Resource Category ..................................................................................................................35 Defining Person Responsible for Work Centre ...................................................................................36 Standard Value Keys...........................................................................................................................37 Defining Formula Parameters for Resources .....................................................................................38
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3.5 3.6 3.7 3.8 3.9 3.10 3.11 3.12 3.13 3.14 3.15 3.16 3.17 3.18 3.19 3.20 3.21 3.22 3.23 3.24 3.25 3.26 4.
Defining Formula for Resources.........................................................................................................39 Task List Usage...................................................................................................................................40 Define Capacity Planner.....................................................................................................................41 Define Number Ranges for Master Recipe..........................................................................................42 Recipe Status.......................................................................................................................................43 Recipe Usages.....................................................................................................................................43 Define Planner Groups .......................................................................................................................44 Control key for Master Recipe ............................................................................................................44 Define Capacity Categories ................................................................................................................45 BOM Status .........................................................................................................................................46 Process Order Type ............................................................................................................................47 Number Ranges for Process Order .....................................................................................................47 Define Production Scheduler ..............................................................................................................48 Define Production Scheduler Profile ..................................................................................................49 Scope of Check....................................................................................................................................50 Define Checking Control ....................................................................................................................51 Define Scheduling parameters for a process order.............................................................................52 Defining Parameters for Order Confirmation ....................................................................................53 Assigning Material Types to Task List ................................................................................................54 Define Material Types Allowed for BOM Header...............................................................................55 Defining Order Type-Dependent Parameters .....................................................................................56 Assigning Process Instructions to Control Recipe Destinations .........................................................57
BATCH MANAGEMENT.........................................................................................................................59 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9 4.10 4.11 4.12 4.13 4.14 4.15 4.16 Activate Document Management for Batches .....................................................................................59 Defining Batch Level...........................................................................................................................59 Activating Automatic Batch Number Assignment ...............................................................................59 Maintain Internal Batch Number Assignment Range..........................................................................60 Define Batch Creation for Production Order / Process Order...........................................................60 Define Process Order Condition Tables .............................................................................................61 Define Process Order Access Sequences ............................................................................................61 Assign Search Procedure to Process Order and Activate Check........................................................62 Activating batch-specific Unit of Measures ........................................................................................63 Edit Batch-Specific Material Unit of Measure....................................................................................63 Define Calculation of Proportion Quantity from Base Quantity ........................................................64 Maintain Period Indicator ..................................................................................................................64 Activating Expiration Date View per Plant.........................................................................................65 Define Process Order Strategy Types .................................................................................................65 Define Search Procedure to Process Order........................................................................................66 Activating Batch Derivation................................................................................................................67
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4.17 5.
DOCUMENT MANAGEMENT ...............................................................................................................68 5.1 5.2 5.3 Define Number Ranges for Document Numbers .................................................................................68 Define Document Types ......................................................................................................................69 Define Data Carrier............................................................................................................................70
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CLASSIFICATION SYSTEM ..................................................................................................................72 6.1 6.2 Define Characteristics Groups ...........................................................................................................72 Define Characteristics Status..............................................................................................................73
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This document captures the required configurations details in SAP system to meet the business requirements as envisaged in the Design Stage (Business Blue Print Stage) for Project, Claris SAP Implementation Production Planning Module. The configuration steps have mappings to corresponding menu path to where the configuration has been done in the IMG (Implementation Guide). The documentation provides visibility to all project teams members on the proposed system settings and changes. It is an important document for all future references in terms of system configuration. All future changes or updates to the system should be done based on this and the documentation updated accordingly. This volume contains details on the configuration requirements for the Production Planning module for Claris Life Sciences pertaining to Master Data This document should be read in conjunction with: 1. Process definition document 2. Key Data Structures
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2.
PRODUCTION PLANNING
2.1
Plant 1001
MRP Controller 101 102 103 104 105 106 107 108 109 110 101 102 103 104 105 106 107 108 109 110 101 102 103 104 105 106 107 108 109 101
Description RM Injectables PPM Injectables SPM Injectables TPM Injectables Production Inj. Packing Inj. Engineering Inj. Lab Mat.Injectable HK & Admin Captive Consumptn RM Infusion PPM Infusion SPM Infusion TPM Infusion Production Inf. Packing Inf. Engineering Inf. Lab Mat.Infusion HK & Admin Captive Consumptn RM API PPM API SPM API TPM API Production API Packing API Engineering API Lab Mat. API HK & Admin Utility for Clarion
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1002
1003
1004
Configuration Document SAP PP-PI
2.2
MRP Type
Implementation Guide for R/3 Customizing (IMG) Production Material Requirements Planning Master Data Check MRP Types SPRO MRP type to assign the procedure to be used to plan a material and to control, which MRP parameters can be, maintained for the material in the material master record. MRP type is assigned in the material master record The following MRP Types are used for Claris MRP type PD VB ND V1 M0 Description Normal MRP Manual Reorder Level Planning No Planning Manual Reorder Level with External Requirements. Master Production Scheduling
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2.3
Lot Size
Implementation Guide for R/3 Customizing (IMG) Production Material Requirements Planning Planning Lot-Size Calculation Check LotSizing procedure OMI4 Lot-sizing procedures serve to calculate the procurement quantities, that is, the purchase order and production quantities With the lot-sizing procedure we define how the order quantities are determined. A lot size defining the lot-sizing procedure is assigned to every material master record applicable to materials planning. The lot size is defined in Customizing by the combination of the lot-sizing procedure and the lot-sizing indicator. Lot Size Key EX FX WB MB Description Lot for Lot Order Quantity Fixed Order Quantity Weekly Lot Size Montly Lot Size
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1002
2000
In-house Production in Infusion In-house Packing in Infusion External Procurement Traded Products Loan Licence
2.5
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2.6
Menu Path
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2.7
Scheduling Parameters
Implementation Guide for R/3 Customizing (IMG) Production Capacity Requirements Planning Operations Scheduling Define scheduling parameters for planned orders OPU5 In this step we define the parameters for scheduling planned orders for each plant, order type and production scheduler. This comprises the following settings: Scheduling levels (detailed-, production-rate and rough-cut scheduling) Date adjustment when deadlines are exceeded Scheduling control for detailed scheduling Reduction Scheduling parameters for planning scenarios for long-term planning/simulation Scheduling Parameters for the Planned Orders are same for all the Plants as defined below: Parameters Detailed Scheduling Horizon Rough Cut Scheduling Horizon Scheduling Levels Adjust Dates For Capacity Scheduling Scheduling type 90 90 Via Detailed Scheduling Adjust basic dates, adjust dep reqmts to operation date Always basic dates, dep reqmts to operation dates Backwards Values
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The following SMK are maintained for plants 1001, 1002 and 2000. For C&Fs, C&As treated as plants, the SMK are 000
Plant 1001
1002
2000
SMK Z00 Z01 Z02 Z03 Z04 Z05 Z00 Z01 Z02 Z03 Z04 Z05 Z01
Opening per 000 001 000 000 000 000 000 001 000 000 000 000 003
Float Before Prd 000 000 001 001 001 001 000 000 001 001 001 001 000
Float After Prd 000 000 001 002 003 004 000 000 001 002 003 004 000
Release Peri
000 000 000 000 000 000 000 000 000 000 000 000 000
Description
selected during the planning run. Here, a sequence is usually determined which is used to select a valid BOM via the criterion "Usage". For all the plants the selection id is set as 01
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Menu Path
OMP2 In this step, we define versions to be able to: differentiate between different planned independent requirements indicate the transfer of requirements from previous planning levels (for example, the sales plan from SOP) simulate requirements planning in long-term planning We have maintained versions for all the twelve months of the year and for requirement plan Requirement Plan 01 02 03 04 05 06 07 08 09 10 11 12 Description January version February version March version April version May version June version July version August version September version October version November version December version
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group will be maintained as 40, for other materials at Manufacturing plants the strategy group will be maintained as 10, warehouse & at C&Fs strategy group is 11 Strategy 10 11 40 Description Make to stock, used for Domestic Requirement PIR Gross demand from C&F Planning with final Assembly, used for International Sales order
Working days)
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Rounding Profile
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For Claris we have used the standard Usage as1 for Production Usage 1 Description Production
Description
The Reasons mentioned below are currently maintained at manufacturing plants 1001, 1002 (Injectable and infusion)
Variances
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Menu Path
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Menu Path
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3.2
Person Responsible
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3.3
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3.4
Menu Path
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3.5
Menu Path
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3.6
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3.7
1002
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Recipe Status
Implementation Guide for R/3 Customizing (IMG) Production Planning for Process Industries Master Data Master Recipe Data for Recipe Header Define Recipe Status OP46 The recipe status determines: Whether a recipe is released for use in process orders Whether a recipe is released for costing Whether a consistency check is carried out before the recipe is posted When a master recipe is created, a status must be assigned to it. This status can later be changed according to the processing stage of the recipe. Together with the recipe usage, the recipe status is used to create priority sequences that serve as a basis for the automatic selection of recipes during order creation, capacity planning and costing. The following status are being maintained for Recipe Plant 1 4 Description Created Released (general)
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Control keys can be used as follows: In resources: The control key we enter here is referenced or copied to the corresponding operations, phases and secondary resources of the master recipe. In the master recipe When creating operations and phases as well as when allocating secondary resources: In the process order when maintaining operations, phases and secondary resources: When we create a process order, the system copies the control keys we have maintained in the master recipe to the order. They can still be changed in the order if there is no reference to the resource. For Claris we are maintaining the following control keys Control Key ZP01 ZP02 ZP03 ZP04 ZP05 ZP06 ZP07 Control key Description Process manufacturing QC : Scheduling and MIC Process mfg., Inspection, AutoGR QC : MIC only Process manufacturing with AutoGR Process manufacturing-Bulk Preparation QA : Scheduling
Menu Path
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Menu Path
CO82 In this menu option, we define the number ranges for orders. Each order is uniquely identified by an order number within one client. We allocate each order to a number range group via the order type. We can allocate several order types to the same number range and thus the same interval.
When we create an order, the SAP System automatically assigns a consecutive number from the number range that we have defined. The number range defined are mentioned below Order Type C001 C002 C003 C004 C005 Number Range 1000000000-1099999999 110000000- 1199999999 120000000- 1299999999 130000000- 139999999 140000000- 1499999999
materials within production activity control. In a production scheduling profile, we can Specify that in a process order particular business transactions be carried out in parallel. Automatic batch creation on order creation. Batch creation on order release For Claris we are marinating the following Production Scheduler Plant 1001 1002 101 102 101 102 Production Scheduler Production Packing Production Packing Description
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W/o Subcontracting Check without RLT No Stor. Location Inspection Checking period Include Purchase orders Include Purchase Indents Include dependent reqmts Include reservations Include Sales Reqmts Include deliveries Include shipping notification Include Dependent reservations Include released Orders Include Planned Orders Include Production Orders Include receipts in Past and future
No Yes No No No No No No No No No No No No No No
Configuration Description
In this step we define the following: Whether an availability check is to be carried out when we create or release an order Whether an availability check is to be carried out when we save an order that has been created or released Which checking rule is to be used What effect a material shortfall is to have on the creation or release of an order For all the manufacturing plant, the Check on the Material will be done during the Creation and Release of the Process Order. If there is material short falls No release will be carried out
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over delivery tolerance in the order header Check on the dates Logs Goods Movement Propose confirmed data For all the Process Order types to the respective plants, all the indicators will be on and check on over delivery / under delivery will also be not checked.
Configuration Description
Only materials of the material types allocated in this step can be allocated to a master recipe at the header level, that is, as the material to be produced. For task list type 2 Master recipe the following types have been assigned Task ListType 2 2 2 2 2 2 Material type FERT HALB HAWA HIBE ROH ZERT
Menu Path
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The Following data is maintained for Claris BOM Usage Material type 1 All material Types
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QA QC SC
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4.2
4.3
Menu Path
OMCZ In this activity we activate internal batch number assignment. We define whether internal batch number assignment is allowed for goods receipts that have an account assignment The internal batch number assignment is activated
4.4
4.5
For plants 1001 and 1002 for order types C001 to C004 we have defined Automatic batch creation on order release and classification carried out in the background
4.6
4.7
Description
process orders. We have Defined the Order Sequence C003 which determines Batch for each Material Type
4.8
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UOM
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search criterion during batch determination Strategy Description Type ZC01 Mat.Type/Mvt/Plant
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