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8/7/2019 Scen Overview en HR PP
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J64: ProductionPlanning andDiscreteManufacturingOverview
SAP AG
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SAP AG 2006, Discrete Manufacturing (J64)
Business View Production Planning and DiscreteManufacturing
Business Benefits CostingProduction
PlanningBusiness Benefits
Costing Run:
The purpose is to calculate pricesfor the selected materials which arethen updated in the material masterrecords as the standard price. Thestandard price is used to valuategoods movements within the
company. The price update involvestwo steps: marking the calculatedprice (that is, setting this as the
future price of the material) and thenreleasing it (making it the currentstandard price). Before you canmark the prices, you have to allow itfor the company.
Production Planning:
This scenario describes a typicalplanning process starting withrough-cut planning. The previousyear's sales figures can be used asa basis. Rough-cut planninginvolves long-term planning with a
time frame of approximately oneyear. The planning data istransferred from SOP to Demand
Management. DemandManagement generates primaryplanning requirements, which are aprerequisite for the subsequentmaterial requirements planning(MRP) run. The MRP run is short-term planning, with a maximum time
frame of four weeks. In MRP, theBOM for the material is exploded
and planning takes place right downto component level. As a result,planned orders are generated forthe material to be produced. Ifinsufficient warehouse stock isavailable, purchase requisitions forthe raw materials required arecreated.
Edit Costing Run
Creating PlannedIndependent
Requirements
Creating PlannedOrder in MRP
Converting a PlannedOrder to Production
Order
Update Prices
Creating Rough Cut
Plan
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SAP AG 2006, Discrete Manufacturing (J64)
Business View Production Planning and DiscreteManufacturing
Business Benefits CostingProduction
PlanningBusiness Benefits
Entering Goods IssueforBOM Components
Entering GoodsReceipt for
Manufactured Goods
Creating OrderConfirmation
Comparing Plannedand Actual Costs
Releasing ProductionOrder
(Batch Determination)
Shop FloorControl:
When a planned order is convertedto a production order, the product,the order quantity and the basicorder date are adopted from theplanned order. The production orderis released and the BOM
components are also reserved forproduction. Automatic batchdetermination based on the
expiration date is performed duringproduction order release. Thegoods issues can be postedmanually before order processingand the goods receipts are postedmanually as well. To collect activitycosts, you create order
confirmations.Target costs for the order lot size
are calculated when the order iscreated (preliminary costing).During the production process,costs incurred during production areupdated to the order, which enablesyou to keep track of and comparetarget costs and actual costs at anytime (simultaneous costing).
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SAP AG 2006, Discrete Manufacturing (J64)
Business View Production Planning and DiscreteManufacturing
Business Benefits CostingProduction
Planning
Calculating Work inProcess
Calculating Variances
Revaluation at ActualPrices
Calculating ActualOverhead
Cost Object Controlling:
Cost object controlling in discretemanufacturing is an area in costaccounting that assigns the costsincurred in the production of
company activities (such asinternally manufactured materials)to those activities. Product cost byorder enables you to analyze costsat the level of manufacturing orders,
process orders, and productionorders. In product cost by order, themanufacturing orders themselvesare the cost objects. Costs chargedto manufacturing orders are usually
analyzed and settled by lot. Thismeans that variances can only beanalyzed after the entire plannedproduction quantity has been putinto inventory. The settings inProduction Planning & Control (PP,PP-PI) are required to costmanufacturing orders as part ofproduction execution.
Business Benefits
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SAP AG 2006, Discrete Manufacturing (J64)
SOP Process Flow
SOP Process Flow
Create Sales Plan
Create Production Plan
Transfer Planning Values to
Demand Planning
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SAP AG 2006, Discrete Manufacturing (J64)
Convert
Planned Order
Dependent
Reqmts
Reservations
Warehouse
Material Reqmts
Planning
Materials Requirement Planning - MRP
Demand
Program
Planned Ind.
Requirements
Production
Order
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SAP AG 2006, Discrete Manufacturing (J64)
Work Center
Work Center 3220
Routings Costing Scheduling
& Capacity
1010,-
2150,-
3160,-
Default values
Routings
Costing Data Sched. Data
Capacity Data
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SAP AG 2006, Discrete Manufacturing (J64)
Routing Work Center / Operation
Routing Header
Operation 10:
Labeling and Packaging
Material Components
Work center
Control key
Standard values
Activity types
Description
....
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SAP AG 2006, Discrete Manufacturing (J64)
A single-level BOM representsthe relationship between
an assembly and its components
Bill of Material
C10150
Finished good
3
FERT
PD
C10150
Finished good
3
FERT
PD
C30380 (12 KG)
Semi-finished
good 34
HALB
PD
C30380 (12 KG)
Semi-finished
good 34
HALB
PD
C40660 (12 PC)
Raw material 11
ROH
PD
C40660 (12 PC)
Raw material 11
ROH
PD
C50210 (1 PC)
Packaging
material tray 1
VERP
PD
C50210 (1 PC)
Packaging
material tray 1
VERP
PD
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SAP AG 2006, Discrete Manufacturing (J64)
Individual ConversionIndividual Conversion
Planned
orders
Production
orders
Collective ConversionCollective Conversion
Planned Order Conversion
Production
orderPlanned
orders
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SAP AG 2006, Discrete Manufacturing (J64)
Specify order typeSpecify order type
Define order itemDefine order item
Copy routingCopy routing
Lead time schedulingLead time scheduling
Copy bill of materialCopy bill of material
Optional changesOptional changes
Save production orderSave production order
FridayJuly
23 1999
TuesdayDecember
14 1999
Requirements planningRequirements planningRequirements planningRequirements planningManuallyManuallyManuallyManually
Availability checkAvailability check
AutomaticallyAutomaticallyAutomaticallyAutomatically
Optional (Customizing)
Production Order Creation
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SAP AG 2006, Discrete Manufacturing (J64)
Order proposal
(planned order)
Order creation
Availability
check
Order release and
batch determination
for components
Order settlement
Confirmations
Order headerOrder header
Operations
Components
Costs 2050
100
Material withdrawal
Goods receipt
Production Order Processing
Production Order
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SAP AG 2006, Discrete Manufacturing (J64)
Material
Goods movementGoods movement
Material
document
Accountingdocument
Warehouse
OperationOperation
Mat. comp.Mat. comp.
Prod.Prod. orderorder
CostsCosts
All materials are batch controlledAll materials are batch controlled
Update of stock quantitiesUpdate of stock quantities
Update of stock valuesUpdate of stock values
Goods Movement
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SAP AG 2006, Discrete Manufacturing (J64)
Goods issueposting
Materialdocument
Acctg.document
Updating stock quantitiesUpdating stock quantities
Updating stock valuesUpdating stock values
Reducing reservationsReducing reservations
Calculating actual costs and upCalculating actual costs and up--
dating the orderdating the order
Goods Issue
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SAP AG 2006, Discrete Manufacturing (J64)
Costing variant
Display planned/actual costs
Cost elements Cost itemization Cost component split
Planned costsPlanned costs
Material costs
Costs for externalprocurement
Production costs
Material overheadcosts
Production overhead
costs
Costs for external
processing
Cost elementsCost elements:: PhasesPhases
Gen. operation values
Standard values
Control key costing
indicator
ResourcesResources
Formula key forcosting
Cost center
Activity type
Formula constants
Cost calculationlog
Ind. "Rel. to costing"
Price
MaterialMaterial componentscomponents
OrderOrdertypetype / Plant/ Plant
Production Order - Preliminary Costing
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SAP AG 2006, Discrete Manufacturing (J64)
Production order costProduction order cost
Overhead calculationsOverhead calculations
- Work center
- Standard value
- Quantities
- Cost center
- Activity types
- Formulas
- Activity types
Operation
Internal activities costsMaterial costs
Cost of Production Order
- Quantities
- Prices
Work center Cost centerMaterialcomponents
- Periods
Activity cost
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SAP AG 2006, Discrete Manufacturing (J64)
OrderStatus
Pre-Released or Released Partially Delivered Finally Delivered or Technically Completed
Variances
Delivery
Value
Actual Costs
WIP at
Actual Costs
=WIP at
Actual Costs
=
-Delivery
Value
=
-
WIP and Variance Calculation in Lot-Based Cost ObjectControlling
Actual Costs Actual Costs
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SAP AG 2006, Discrete Manufacturing (J64)
Material
600
Product cost planning
Lotsize 1 PCCOCO--PCPC
Production OrderMat. C10150
8001.200
4002.400
-2.000
400
MaterialProductionSurcharge
GR
Variances
Actual Cost
CO-
PC
Material MasterStandard Price = 2000
Target Version 0
Price 150
Qty 150
Structure 100
Scrap 0Lotsize 0
Production
1100
Surcharge
300
Warehouse Price difference
Financial Accounting
2000 400
SettlementFI
CO-
PA
Settlement of Order (Example)
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SAP AG 2006, Discrete Manufacturing (J64)
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