Process Industry
Manufacturing
Purpose :
Introduction to SAP PP PI - Process Manufacturing
OVERVIEW
Process Manufacturing
Differences b/w Process & Discrete Mfg.
Master Recipe
Resource
Process Order
Availability of Material
Data Flow During Process Manufacturing
PROCESS MANUFACTURING
It is a form of an industry type- where the products once
manufactured, cannot be easily dis-assembled.
It is also really not possible to rework the ill-manufactured
end products, back in to raw materials.
For example: products such as food products,
chemicals, medicine, towels, paper, steel etc.
With the above definition of a process industry in
perspective, SAP offers SAP PPPI or SAP PI which can be
used to implement business processes in a process
industry.
DIFFERENCES B/W PROCESS & DISCRETE MFG.
1. A Master Recipe is used instead routing
2. Process order is created instead production order
3. A master recipe carries a concept of operations
assigned with phase whereas it is not available in
discrete manufacturing
4. Resource (work center in discrete) are assigned to
the operation and all the phases assigned to the
operation uses the same resource
MASTER RECIPE
It is similar to routing in discrete manufacturing
One can create task list groups and then assign the
material
The transaction code to create a master recipe is
C201 (Change is C202 and Display is C203
After the BOM is exploded in the master recipe, we
can enter into material quantity calculations screen
through the path – Goto > Material Quantity
Calculation
Below methods will be used to enter the formula –
1- Once you are in the material quantity calculations
screen, keep your cursor on the field for which you want to
change through the use of formula and press the “Select
formula” button.
2- In the formula box, you can enter the formula equation
that derives the output field value.
3- While creating the formula you can double click on the
variables that you want to include in the formula or just
keep the cursor on the variable and press the button –
“Insert in formula”
4- The operators like +, -, *, /, DIV, MOD can be selected on
the screen.
RESOURCE
To manage the objects and persons involved in the
production process
You assign resources to- operations & phases in master
recipe
Data managed in the resource serves as a basis for
scheduling, capacity requirements planning, and
costing.
Resources in PP-PI can be accessed using t-code
CRC1/2/3.
Major difference between a work center and resource is
work center category as shown in below screenshot -
Production line
Processing unit
Create resource
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 -transaction code CORY
Creating a Process Order
Transaction code COR1 (Change is COR2, Display is COR3).
Create a process order from the conversion of a planned order using the
transaction code COR7 (individual conversion) or COR8 (collective
planned order conversion).
Following activities are carried out automatically or manually in SAP PPPI-
Pull in the Master Recipe
Pull in the Relevant Bill of Material
Batch Allocation is carried out automatically /manually in process order
System executes all the formulas of the material quantity calculations
Creation of the process order creates a reservation number for the
process order
Creation of the process order does not create a control
recipe nor can you print any shop floor papers
The release of the process order will create the control
recipe of the process order
The process order creation process- the release, manual
confirmation, goods issues, goods receipts, i.e., the overall
execution process of a process order is exactly same as that
of the production, but apart the creation of a control
recipe.
AVAILABILITY OF MATERIAL
Before you start production, we can check whether all the components
allocated to the process order are available on the calculated
requirements dates
In a process order, the system only checks material components that
are relevant to inventory management and have the item category “L”
(stock component).
Availability checks can be triggered either automatically or manually:
The availability of components in an order can be checked
automatically during order creation and/or order release. In
Customizing for Process Orders, you specify per order type and plant
whether the availability is to be checked automatically.
We can always trigger a manual availability check.
The checking scope is defined via the checking group & valid
checking rule :
Which MRP elements are taken into account in the check
Which inventory categories are taken into account
Whether the replenishment lead time is taken into account.
Checking Group –
If the materials to be checked are to be locked during the
availability check.
Used to group materials that are to be checked according to the
same criteria.
Check Rule –
It defines –
which MRP elements are to be checked
which inventory categories are to be checked
How is the Availability of Materials Determined –
according to the ATP method
At What Level is the Availability Check Carried Out –
The availability check can be carried out at plant, storage
location or batch level
Availability Check in Process Order –
In the availability log - result of the check, A list of the missing parts, a
list of the reservations that could not be checked
Used to group materials that are to be checked according to the
same criteria.
To check the availability of all material components in the order, choose
Process order → Functions → Availability check → Material - ATP
Configuration of ATP
Availability Check in Process Order
