Process documentation PP/DS With SAP R/3 

Purpose

This scenario describes generic production planning and execution for in-house produced products with an SAP APO system and an SAP R/3 system, without making detailed reference to the source of the requirements. With

Production Planning and Detailed Scheduling (PP/DS) you plan critical products that are produced on bottleneck resources, on the basis of production process models. You use the SAP R/3 for master data maintenance, for the manufacturing execution functions (for example, confirmations, goods receipts postings or purchasing) and for planning uncritical products. You plan the critical products using PP/DS and transfer the planning results to SAP R/3. Here, you complete the planning for uncritical products in the BOM structure, that you do not plan in SAP APO.

Prerequisites

System prerequisites for SAP APO and SAP R/3

For information on system prerequisites, see

Integration of SAP APO and SAP R/3
  • Checklists for Setting up the System Infrastructure

    SAP R/3 master data

    • You have
    • excluded the products that you are planning in SAP APO from the planning in SAP R/3
    • You have
    • defined production versions in SAP R/3. For the initial transfer, the production versions from SAP R/3 are created in SAP APO as production process models.

      Initial transfer of master and transaction data

      You have executed the initial transfer of all SAP APO relevant master data and

      transaction data from SAP R/3 to SAP APO. You must transfer the master data of the products that are to be planned in SAP APO, and the master data of all components. The data is transferred to the active model 000 and the active planning version 000.

      Master data that is transferred from SAP R/3 to SAP APO

      SAP R/3 master data

      Transferred master data in SAP APO

      Plants (storage locations, distribution centers)

      Locations

      Vendors

      Customers

      Material masters

      Product masters

      Production versions (BOMs, material lists, routing – recipe)

      The production versions from SAP R/3 are created in SAP APO as production process models.

      Work centers

      The capacities of the work centers are created as resources in SAP APO.

      Scheduling agreements

      External procurement relationships

      Contracts

      Purchasing info records

      Transaction data that is transferred from SAP R/3 to SAP APO

      SAP R/3 transaction data

      Transferred transaction data in SAP APO

      Sales orders

      Sales orders

      Production or process orders

      Production or process orders

      Manual reservations

      Manual reservations

      Purchase requisitions or orders

      Purchase requisitions or orders

      Planned orders

      Planned orders

      Planned independent requirements

      Planned independent requirements

      After the initial transfer, changes to data in the master or transaction data are filtered and routed automatically through an active data channel, which uses ALE and BAPI technology. Stock and requirements information is automatically transferred from SAP R/3 to SAP APO via RFC. Procurement proposals created in SAP R/3 are automatically transferred to SAP APO. Procurement proposals created in SAP APO can be transferred to SAP R/3

      automatically or as required. Any changes made in SAP APO are transferred automatically to SAP R/3; the same applies in the opposite direction. For more information, see Integration of Master and Transaction Data.

      Customizing in SAP APO

      You have maintained the following settings under Global Settings in Customizing for Production Planning and Detailed Scheduling (PP/DS):

      Global Parameters and Defaults for PP/DS

      Tab page

      Use

      Planning

      Here, you specify the settings for planning orders, for example

      • If the system creates a number for the orders created in SAP APO
      • When PP/DS orders are transferred to SAP R/3
      • With which detailed scheduling strategies the system plans orders in the various areas of PP/DS
      • Which planning type the system uses for creating orders in SAP APO (for example, production process model)
        The planning type set here is a default value; in the location product master you can specify a planning type specific to the location product.

      ATP categories

      You use categories to display the description of the relevant receipts and requirements in the interactive planning for PP/DS Since SAP APO is configured for integration with SAP R/3, you only need to specify categories for an OLTP system if this system is not an SAP R/3 system.

      You maintain the categories in Customizing for Global Available-to-Promise (Global ATP Check) under General Settings Maintain Categories.

      SAP APO master data

      You have completed the data in the master data according to your planning requirements and have assigned it to Supply Chain Model 000 (see

      maintenance of master data).

      Process Flow

      The processes involved for products produced in-house include:

      1. Planning receipts for the products planned in SAP APO using PP/DS
      2. For more information, see

      PP/DS Process.
    • Transferring receipts to SAP R/3
    • Completing the planning for the components planned in SAP R/3
    • Planning in PP/DS to solve planning problems or to create the order sequence
    • Transferring and converting in SAP R/3
    • Execution in SAP R/3
    • The following graphic shows the process flow from the receipt of a requirement in SAP APO to the goods receipt in SAP R/3.

      Process flow of an order produced in-house in SAP APO and SAP R/3

      This graphic is explained in the accompanying text

      Completing the planning for the components planned in SAP R/3

      When transferring a requirement, only the products that are relevant for SAP APO are transferred from SAP R/3 to SAP APO. SAP APO plans these products that are displayed in a component list, as component list A, for example. The orders for component list A are transferred back to SAP R/3. The BOM is re-exploded in SAP R/3. This causes a new component list to be created, such as component list B. SAP R/3 executes a comparison of the two lists:

      Comparison of Component Lists in SAP R/3 and SAP APO

      Component

      Consequence

      Available in lists A and B

      List A is valid. The quantity and date determined by SAP APO are used.

      Only available in list B

      Planning of the component is completed in SAP R/3. The quantity is determined during the BOM explosion and the date is determined from the start of the first activity of the order.

      Only available in list A

      This is not permitted. The complete BOM must be maintained in SAP R/3.

      The components that are to be planned in SAP R/3 (only in component list B) are planned during the next MRP run.

      Execution Functions in SAP APO

      You are able to trigger the conversion of planned orders and purchase requisitions into production orders or purchase orders directly in SAP APO. To do this, you set the conversion indicator for the orders to be converted in PP/DS. Orders for which this conversion indicator is set are immediately automatically converted after transfer to SAP R/3. The converted orders are sent back to SAP APO with a changed ATP category (for example, Preq for purchase requisition becomes PchOrd for purchase order). If you transfer planned orders and purchase requisitions, without the conversion indicator set, to SAP R/3, and only carry out the conversion there, the dates planned in SAP APO are overwritten. For more information, see

      Transferring Orders to the OLTP System.

      Execution Functions in SAP R/3

      The following execution functions are performed in SAP R/3.

      Execution Functions in SAP R/3

      Function in SAP R/3

      Reaction in SAP R/3

      Reaction in SAP APO

      Scheduling to determine costs (Controlling)

      Scheduling is performed to determine costs. This information is only required by Controlling. The data determined here is not used for production planning.

      The data determined during detailed scheduling in SAP APO is not changed.

      Printing the pull list

      You print the pull list in SAP R/3.

       

      Withdrawing components

      The requirements and component stock are reduced.

      The requirements and component stock are reduced synchronously in SAP APO.

      Confirmation

      Quantities are reduced. When you confirm partial quantities, the operation is moved to the confirmed start date and keeps its original duration.

      When you confirm an operation, the operation receives both the confirmed start and finish date.

      Quantities are reduced and the operations synchronously receive the same dates as in SAP R/3.

      Confirmations or final deliveries lead to reduction of the open quantity of the corresponding order in SAP APO to zero. The order is no longer displayed in the product view.

      Posting goods receipt

      The order quantity for the receipt is reduced and the stock is increased.

      The order quantity is reduced and the stock is increased synchronously in SAP APO.

      See also

      • For information on make-to-order production with an SAP R/3 and an SAP APO, see
      • Capable-to-Promise (CTP).
      • For information on planning externally procured products in SAP APO, see
      • Procurement Scheduling Agreement and Planning and Source Determination in External Procurement