Material Quantity Calculation (SAP Library - Process Orders (PP-PI-POR))

Material Quantity Calculation

Use

You use this function for a production version of a master recipe or a process order to visually reproduce the dependencies between the following values:

Quantity and properties of a product, such as the active ingredient proportion

Quantity and properties of material components, that is, material items and their batches

Operation and phase quantities

The scrap to be expected for an operation or phase

You need this function to adjust the quantities defined in the bill of material (BOM), master recipe, or process order in the following cases:

To calculate the component quantities if they are not proportional to the product quantity or if different active ingredient concentrations of batches must be taken into account
To calculate the product quantity, that is, the base quantity of the master recipe or the order quantity if it must be adjusted to modified component quantities. This may be the case if, for example, a batch of a component is always used up completely.
To calculate the expected phase scrap if you want it to be displayed in the phase data in the order (Quantities/Activities screen) and make it available for planned/actual evaluations carried out in the Logistics Information System
To calculate operation and phase quantities if they are not identical to the product quantity. You may want to do this, for example, if you must take the quantity difference caused by the scrap produced into account.

Integration

You enter the formulas for material quantity calculation in the master recipe or process order. If required, you transfer the formula results from the recipe to the BOM.

Material quantity calculation is always performed during further processing when you use the production version to select a recipe and BOM and then carry out scheduling. This means that it is performed, for example, when you create a process order, convert planned orders, or during product costing, but not when you carry out material requirements planning without a detailed plan.

In material requirements planning and product costing, material quantity calculation is used to calculate the material and operation quantities that are, for example, necessary for reservations or direct cost statements.

In the process order, material quantity calculation determines the order-specific quantities. The formulas for the calculation are taken from the master recipe. However, you can change them in the order and start the calculation again, if, for example, the basis for the calculation has changed due to batch determination. The quantities calculated in this way are used as the basis for reservations, scheduling, capacity requirements planning, and costing.

Prerequisites

To be able to use material quantity calculation in a master recipe, you must have defined a production version for the master recipe.

To transfer the data from material quantity calculation from a master recipe to the process order, you must create the process order with the corresponding production version.

To transfer the scrap calculated in material quantity calculation to the corresponding phase in the process order, you must have activated scrap management in the parameters of the relevant order type (see Customizing for Process Orders).

Features

Formula Definition

You can use the following functions in material quantity calculation to define formulas:

The common arithmetical operators and functions as well as references to quantities and material properties (see Basic Functions of Material Quantity Calculation)

Functions that you can use to perform material quantity calculation based on batch data (see Material Quantity Calculation with Batch Data)

This function enables you, for example, to use material quantity calculation together with active ingredient management of the Batch Management component to plan the quantity structure of your orders on the basis of exact active ingredient quantities.

Important Information about Value Processing

Depending on the type of value to be calculated, also bear in mind the following:

The formulas for the product and component quantities may not mutually refer to each other.
If you have planned a scrap quantity for a product in the material master record or the order header, the system automatically increases the product and component quantities during quantity calculation without formulas.

If you have planned a scrap quantity for a component in the material master record, the BOM, or the material list of the process order, the system automatically increases the component quantity during quantity calculation without formulas.

If you perform quantity calculation with formulas, the system does not automatically take the planned scrap quantity into account. If required, you must explicitly include it in the formula.

The scrap quantity calculated for a phase does not automatically reduce the succeeding phase quantities. However, you can use the formulas of the operation and phase quantities to visually reproduce the quantity difference caused by the scrap produced.
In collective orders, material quantity calculation is only supported within the leading order. Header quantities and component quantities of subordinate orders are calculated in proportion to the product quantity. For this reason, do not enter formulas for:

Directly-produced components of the leading order
Materials or phases of subordinate orders

Performing Material Quantity Calculation

You can start material quantity calculation as follows during production planning:

Automatically together with functions during which scheduling is carried out (see Integration above)

Material quantity calculation calculates component, operation, phase, and scrap quantities for which a formula has been defined. Product quantity calculation is not carried out during automatic material quantity calculation.

Component quantities for which no formulas are defined have already been calculated in proportion to the product quantity (for example, during order release or BOM explosion).

Manually in the master recipe or process order

Here you decide whether the product quantity is calculated in addition to the component, operation, phase, and scrap quantities.

When you carry out product quantity calculation, the system automatically recalculates the component quantities with a formula afterwards. Note, however, that component quantities without a formula are not adjusted to the modified product quantity.

Activities

Defining Material Quantity Calculation

Performing Material Quantity Calculations