146 Scen Overview en XX

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Make-to-Stock Production – Process Industry

SAP Best Practices



© 2011 SAP AG. All rights reserved. 2

Purpose, Benefits, and Key Process Steps

Purpose This scenario provides an integrated platform for batch-oriented process manufacturing. This

supports processes in the following manufacturing industries, chemical, pharmaceutical, food andbeverage industries as well as the batch-oriented electronics industry.

The Sales and Operation Planning process results in independent requirements which are usedin material requirement planning (MRP). Planned orders are converted to process orders formanufacturing 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 receiptsat time of order confirmation. Customer orders decrease the planned independent requirementsat 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 productionquantity

Cost Object Controlling

Key Process Steps Planned Independent Requirements Creation

Material Requirements Planning (MRP)

Make-to-stock production for semi-finished and finished products




Required SAP Applications and Company Roles

Required SAP Applications

Enhancement package 5 for SAP ERP 6.0

Company Roles

Production Planner

Production Supervisor Warehouse Clerk

Shop Floor Specialist




Detailed Process Description

Make-to-Stock Production – Process Industry

Sales-order-independent production using MTS (Make-to-stock) production / process orderprocessing

MRP planning with planned independent requirements gives planned orders for productionas 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-finishedand finished products produced, in conjunction with batch management

Backflushing is used for the packaging material (without batch management) at finishedproduct confirmation

Process order confirmation triggers order controlling and settlement




Process Flow DiagramMake-to-Stock Production – Process Industry

S h o p F l o o r

S p e c i a l i s t

E v e n t

P l a n t

C o n t r o l l e r

Period EndClosing

“General” Plant (181)

Beginning ofPlanning

Cycle

Periodic PlanRevision

MaterialStaging for

PlannedOrders

Confirmationof Production

PickList

C

u s t o m e r

Procurementw/o QM

(130)

S t r a t e g i c

P l a n n e r

MultilevelOrder Report

OrderList

Inventory @Standard.

Cost

Post GoodsReceipt forProcess Order

Goods Issueof Batch

ManagedComponents

GoodsReceiptSlip

S h o p F l o o r

S p e c i a l i s t / W

a r e -

h o u s e C l e r k

GoodsIssueSlip

InventoryConsumption @ Std.Cost

Goods Issuefor BackFlushedComponents

P

r o d u c t i o n P l a n n e r

CapacityEvaluation

Yes

P r o d .

S u p e r v .

MaterialRequirements

Planning at PlantLevel & Evaluation ofStock / Requirement

List

PurchaseRequisition

MRP List Check MaterialAvailability

Change OrderSchedule

PlannedOrders

Material atShopfloorLocation?

CapacityLeveling

OK?

CreatePlanned

IndependentRequirement

sNo

ConvertPlanned Order

to ProcessOrder

LogisticsPlanning

(144)

Yes

No




Legend

Symbol Description Usage Comments

To next / From last Diagram: Leadsto the next / previous page of theDiagram

Flow chart continues on the next /previous page

Hardcopy / Document: Identifies aprinted document, report, or form

Does not correspond to a taskstep in a document; instead, it isused to reflect a documentgenerated by a task step; thisshape does not have any outgoingflow lines

Financial Actuals: Indicates afinancial posting document


Budget Planning: Indicates abudget planning document


Manual Process: Covers a taskthat is manually done

Does not generally correspond toa task step in a document;instead, it is used to reflect a taskthat is manually performed, suchas unloading a truck in thewarehouse, which affects theprocess flow.

Existing Version / Data: This blockcovers data that feeds in from anexternal process

Does not generally correspond toa task step in a document;instead, this shape reflects datacoming from an external source;this step does not have anyincoming flow lines

System Pass / Fail Decision: Thisblock covers an automaticdecision made by the software

Does not generally correspond toa task step in the document;instead it is used to reflect anautomatic decision by the systemthat is made after a step has beenexecuted.

E x t e r n a l

t o

S A P

BusinessActivity / Event

Unit Process

ProcessReference

Sub-Process

Reference

ProcessDecision

DiagramConnection

Hardcopy /Document

FinancialActuals

BudgetPlanning

ManualProcess

ExistingVersion /

Data

SystemPass/FailDecision

Symbol Description Usage Comments

Band: Identifies a user role, such as AccountsPayable Clerk or Sales Representative. This bandcan also identify an organization unit or group,rather than a specific role.

The other process flow symbols in this table gointo these rows. You have as many rows asrequired to cover all of the roles in the scenario.

Role band containstasks common to thatrole.

External Events: Contains events that start or endthe scenario, or influence the course of events inthe scenario.

Flow line (solid): Line indicates the normalsequence of steps and direction of flow in thescenario.Flow line (dashed): Line indicates flow toinfrequently-used or conditional tasks in ascenario. Line can also lead to documents involvedin the process flow.

Connects two tasks ina scenario process ora non-step event

Business Activity / Event: Identifies an action thateither leads into or out of the scenario, or anoutside Process that happens during the scenario

Does not correspondto a task step in thedocument

Unit Process: Identifies a task that is covered in astep-by-step manner in the scenario

Corresponds to a taskstep in the document

Process Reference: If the scenario referencesanother scenario in total, put the scenario numberand name here.


Sub-Process Reference: If the scenario referencesanother scenario in part, put the scenario number,name, and the step numbers from that scenariohere


Process Decision: Identifies a decision / branchingpoint, signifying a choice to be made by the enduser. Lines represent different choices emergingfrom different parts of the diamond.

Does not usuallycorrespond to a taskstep in the document;Reflects a choice tobe made after stepexecution

< F u n c t i o n >


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Appendix

Master Data Used

F29Finished Good MTS PI

(FERT-PD)

B

Batch ManagementB

Bulk

Material

S24Semifinished Good,Liquid

(HALB-PD)

BFIFO

Exp. date

LQLean QM

R15RAW Material

(ROH - PD)

R09RAW Material(ROH - PD)

R19RAW Material(ROH - PD)

LQ

R30RAW Material,

Reorder Point(ROH - VB)

B

FIFO

Master Recipe MR-50002/1 - Packing

Master Recipe MR-50001/1 – Mixing / Bottling

B B

FIFO FIFO


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146 Scen Overview en XX

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