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Process documentationAdvanced Production Integration

 

Advanced production integration allows you to integrate the supply of products to production and the receipt of products from production into your warehouse in SAP Extended Warehouse Management (SAP EWM). It is integrated with the manufacturing order processing in SAP ERP, but it allows you to stage and consume the materials and receive the semi-finished products or finished products in SAP EWM. This means that you can process the warehouse execution for manufacturing orders that have been sent to SAP EWM from SAP ERP even if SAP ERP is not available.

Advanced production integration is integrated with quality management to allow you to perform sample checks on the product during the execution of the manufacturing order. For more information, see Presampling in Production.

Advanced production integration allows you to plan the staging of products for production over a period of time, allowing you to use the space on your production supply area (PSA) more flexibly. You can receive packed products as soon as they arrive from the production line using radio frequency. This allows you to synchronize the material flows between the warehouse and production promptly, which improves inventory visibility in SAP EWM and in SAP ERP.

You can use advanced production integration for production orders in discrete manufacturing or for process orders in process manufacturing.

Process

The following graphic shows the overall process of supply to production and receipt from production. It is followed by an explanation:

  1. You create the manufacturing order (production order or process order) in SAP ERP.

  2. You release the manufacturing order in SAP ERP.

    In SAP EWM, the system generates the expected goods receipt documents for the released orders as part of a regular run.

  3. You perform material staging for the manufacturing order in SAP ERP.

    The system creates a production material request (PMR) in SAP EWM, containing the information about the products needed by production and the quantities needed for the entire manufacturing order.

  4. You plan the staging of the products over the time period when they are required by creating the staging warehouse tasks.

    The system proposes a quantity to stage. This can be the entire quantity required by production or a smaller quantity to stage and replenish at intervals.

  5. You move the goods to the PSA and confirm the staging warehouse tasks.

  6. As production consumes the goods, you post the consumption in the system.

    The system posts goods issue for the consumed products and updates PMR in SAP EWM and the manufacturing order in SAP ERP.

  7. You received goods from production for putaway in the warehouse.

    These can be the finished product of the manufacturing order, by-products or co-products of the manufacturing order, or semi-finished products that are to be stored for use by production later.

  8. The system posts goods receipt for the products in SAP EWM.

    The system communicates the goods receipt SAP ERP.

  9. You create the warehouse tasks for putaway, put away the products in the warehouse, and confirm the putaway tasks.

  10. You set the manufacturing order status to technically completed in SAP ERP. The system automatically completes the PMR in SAP EWM.

  11. You clear the PSA and bring back any unused materials into the warehouse.

  12. You set the manufacturing order status to closed in SAP ERP. The system automatically closes the PMR in SAP EWM.

Example

You have a production line that makes chocolate muffins.

You create a production order in SAP ERP, listing the ingredients needed for the muffins. You release the production order for material staging. The system creates a PMR in SAP EWM containing the ingredients and quantities needed by production. It also creates an expected goods receipt document in SAP EWM, to prepare for the receipt from production.

You plan your staging. Production does not require the entire quantity of each ingredient at the start of the day. The system proposes a smaller quantity. You move that quantity from your warehouse to the production supply area. As production uses the ingredients, you post the consumption of the materials. You stage the same quantity again to replenish the supply.

The system posts goods issue for the ingredients and updates the manufacturing order in SAP ERP.

Production finishes making the first batch of muffins and packs them into cartons. The cartons all have the same kind of muffin in them, and the same quantity of muffins. You use the manufacturing order number to identify the cartons and receive them as they arrive from the production line, because each carton has the same contents.

The system posts goods receipt for the muffins and updates the manufacturing order in SAP ERP.

You put the muffins away in your warehouse.