How Are the
Details of the Order Mapped in SAP APO and SAP R/3?
The following section deals with the following topics:
· Transfer of operations
· Assignment and dates or requirements and receipts
· Flexible component assignment or assignment of a component to an operation segment
· Handling of the goods receipt processing time
· Overlapping, flow manufacturing and interoperation times (queue time, move time, wait time)
· Enhanced integration of reference operation sets
· Product interchangeability
Transfer of Operations – Orders Without Operations in SAP APO
These orders consist of only one activity without modes and capacity requirements, in other words a so-called dummy activity. The scheduled dates from the R/3 order are copied directly to the start and end date of the dummy activity. In SAP APO the order is assigned the same dates as in SAP R/3.
Assignment and dates of requirements and receipts
Operation Assignment of the Primary Product
The header material of a R/3 planned or manufacturing order always lies at the end of the order
The primary product is automatically assigned to the last activity in the order the first time the order is transferred to SAP APO. The main receipt is also assigned to the last activity or the last operation on transfer to SAP APO when an operation or phase is added to the R/3 order.
If the PPM is different, for example, if the main receipt is assigned to another activity and not to the last activity then a planned order with a primary product that is not assigned to the last activity can be created in SAP APO. This usually results in date shifts, at the latest when the order is converted into a manufacturing order. Because the receipt date of the primary product is retained, the activities are shifted as a result of the changed assignment.
If the main receipt is not assigned to the last activity the following issues may arise:
· Date shift between SAP R/3 and SAP APO after return of R/3 order number
· Date shift between SAP R/3 and SAP APO after planned order conversion from SAP APO
· Date shift between SAP R/3 and SAP APO after material requirements planning (MRP) in SAP R/3
· Date shift between SAP R/3 and SAP APO after release of manufacturing orders
Operation Assignment of Components and By-/Co-Products
When an order is transferred from SAP R/3 to SAP APO the components and by- or co-products are assigned to the same operation in SAP APO that they are assigned to in SAP R/3.
If this R/3 operation is not integrated into SAP APO, assignment is carried out as follows:
· Order components, for example, dependent reservations and dependent requirements are assigned to the first activity of the order.
· Co- and by-products are assigned to the last activity of the order.
This assignment is independent of an assignment made in the PPM.
The first activity of the order is usually a setup activity, the last activity is usually process or tear down.
If you have entered operation-related lead time offsets in SAP R/3 this can have the following effects:
When SNP orders are converted into PP/DS orders the material availability date or the availability date changes, even though the order dates do not change.
This can also occur when an order that is transferred to SAP APO is created in SAP R/3 if there is no valid source of supply for in-house production in SAP APO for the material produced. (See SAP Note 429791 – Considering Component Lead Times or Lead Time Offsets)
Flexible Component Assignment
As of Plug-In PI 2003.1 and SAP APO 4.0 you can use flexible component assignment in the production order to control, both in order creation in SAP R/3 and within order integration, from which operation segment (setup, process or tear down) the requirements date of the components is determined (start-setup, start-process or start-tear down). This value if copied to the order for the components.
All components in the order are assigned the same requirements date according to the assigned operation segment (SAP R/3) or the assigned activity (SAP APO).
In integration a component is assigned to the corresponding activity of the operation in the PPM or PDS. This assignment is carried out using the scheduling parameter TCX00-CMACT (Assignment of Material Availability Date Operation Assignment).
Date shifts that are specifically required for certain individual components can be achieved using an offset time in the form of a lead time or lead time offset in the BOM in SAP R/3.
Evaluation
Flexible component assignment is evaluated in integration in the following cases:
· Order integration (planned and production orders)
· Production process model integration (PPM)
· PP/DS production data structure integration (PDS)
If the required activity is not available in the APO manufacturing order the assignment is made to the corresponding activity of the first APO-relevant operation. If this activity is not available either, the assignment is made the to the first activity of the first operation.
Prerequisites in Customizing in SAP R/3
You can define the operation segment in Customizing for Shop Floor Control under Operations → Scheduling → Define Scheduling Parameters for Production Orders on the level Plant, Order Type and Production Scheduler. These settings are transferred to SAP APO for each order.
Settings for flexible component assignment cannot be made in SAP APO.
Goods Receipt Processing Time
The goods receipt processing time (GR processing time) is modeled as an activity in SAP APO. This GR processing time can only be generated if a handling resource exists to which the activity is scheduled and which determines the calendar. The relevant handling resource is the handling-out resource, which you can assign in the location master.
Prerequisites
In SAP APO in the product master, enter a corresponding goods receipt processing time.
If you do not enter a GR processing time in the master data, planned orders are first of all created with a GR processing time in SAP APO and the GR processing activity is not added until the orders are converted into manufacturing orders.
This can result in a date shift in the APO order when the conversion takes place.
Define a handling-out resource in the location master. (See SAP Note 324483 ‑ APO-CIF: Goods Receipt Processing Time)
System Response
The system responds as follows:
...
1. For the goods receipt processing time of a receipt in a PP/DS order, a goods receipt processing activity of type G (Goods Receipt) is created; the receipt is assigned to this goods receipt processing activity.
2. The GR processing activity is scheduled via a handling resource although the GR processing activity does not generate any capacity requirements on this handling resource.
3. The GR processing time entered in the R/3 order is always used for the APO manufacturing order. Changes to the GR processing time in SAP R/3 are also adopted in the APO manufacturing order and the duration of the GR processing time is adjusted accordingly.
Overlapping, Flow Manufacturing and Interoperation Times (Production Orders)
Overlapping of orders means that an operation is started before the preceding operation has been finished.
The system calculates the start and end dates taking into account the minimum send-ahead quantity and minimum overlap time so that the overlapped operations can be executed without any interruption. If two operations that follow one another overlap then the total lead time is reduced.
In overlapping the following operation does not begin before the minimum send-ahead quantity can be made available. If applicable, move times are taken into account.
In flow manufacturing the operations overlap completely. In contrast to overlapping operations, in flow manufacturing all operations that belong to a flow manufactured sequence are extended on the basis of the longest production duration of the sequence.
As of SAP APO 4.0 used with Plug-In 2003.1, overlapping or flow manufactured operations of a production order can be fully integrated into SAP APO. The interoperation times are also transferred to SAP APO.
See SAP Note 604878 ‑ R/3 -> APO: Relationship Durations with Interoperation Times and Overlapping.
Constraints
You should note the following constraints:
· Overlapping is realized only for production orders, not for process orders in SAP APO.
· Only the order-internal overlapping is mapped in SAP APO (not the cross-order overlapping).
· The overlapping can only be mapped between operations of the same sequence type, in other words, either between operations of the standard sequence or between operations of the same parallel sequence.
· Up to and including SAP APO 4.1, overlapping in the standard system can only be mapped when production process models (PPMs) are used.
If you want to use production data structures (PDS) in SAP APO 4.1, see SAP Note 507025 - Examples of Customer Enhancements II.
· You can use the BAdI /SAPAPO/CL_EX_CIF_IP (method ORDER_INB_REL_X_CHANGE) to control whether properties from relationships that already exist in SAP APO are transferred.
· SAP APO does not differentiate between optional and mandatory overlapping. For APO scheduling, the minimum interval defined by overlapping represents a specified minimum interval between predecessor and successor operation.
· Optional overlapping is not taken into account.
· Only the duration of the wait time or the duration of the combination of move and queue time is transferred to SAP APO.
¡ The wait time has the highest priority.
¡ In the case of overlapping, the wait time is not taken into account because overlapping generates scheduled relationships and the wait time is mapped by means of non-scheduled relationships.
¡ The combination of move and queue time is taken into account in overlapping and flow manufacturing.
Prerequisites
The prerequisites for overlapping or flow manufacturing are as follows:
· The operation for which the overlapping was defined and the following operation must be APO-relevant.
· All operations that are involved in flow manufacturing must be APO-relevant.
· Mandatory overlapping is defined for the first operation of the overlapping sequence.
· The minimum send-ahead quantity is greater than or equal to zero.
· All overlapping operations include the activity Process.
· You must define the strategy profile in Customizing under Integration with Other SAP Components → Integration of SAP SCM and SAP R/3 → Application-Specific Settings and Enhancements → Settings and Enhancements for In-House Production → Define Strategy Profiles.
On the tab page Strategy Parameters for Dependent Objects in the area Time Relationships, define that order-internal relationships should always be taken into account.
Overlapping and Flow Manufacturing
In R/3 outbound additional relationships must be generated and attributes changes in order to map overlapped or flow manufacturing operations.
The overlapping of two operations is mapped via two relationships. This generates a start-start relationship or a end-end relationship.
Interoperation Times
In the production order, the following interoperation times (queue time, wait time and move time) can be defined between two operations in SAP R/3:
· Minimum and maximum wait time
· Minimum and standard move time (also from move time matrix)
· Minimum and standard queue time (also from work center)
All interoperation times are take into account in a relationship as an interval.
The durations of the relationships are always displayed in seconds in the PPM.
Move Times and Queue Times
Move times and queue times are always mapped as totals via scheduled relationships in the form of a duration. The process-related minimum interval corresponds to the total of the minimum queue and move time; the planning-related minimum interval is defined via the total of the standard queue and move time.
In overlapping and flow manufacturing, only move and queue times are taken into account because the relationships are always scheduled via the predecessor resource.
The move time is mapped in SAP APO using relationships that are not scheduled using resources (see SAP Note 380141 R/3->APO: Do Not Transfer Wait Times and Move Times). There is no move time matrix in SAP APO.
When manufacturing orders are transferred from SAP R/3 to SAP APO, the move times between operations are determined in the CIF (on R/3 side) from the order on the basis of the R/3 move time matrix and these durations are transferred to SAP APO with the relationships: However, these durations are not scheduled in SAP APO. Calendar, resources and so on are not taken into account.
(See SAP Note 380141 ‑ R/3->APO: Do Not Transfer Wait Times and Move Times).
Whereas in SAP R/3 the queue time occurs at the start of the operation, in SAP APO the queue time (combined with the move time) is taken into account at the end of the operation. In other words a combination of the queue time and the wait time makes the offset of an operation.
Move and/or queue times at the last operation of an order are not taken into account in SAP APO.
Wait Times
Wait times are always mapped in the form of a duration via a non-scheduled relationship. The process-related minimum interval corresponds to the minimum wait time, the maximum interval is defined by the maximum wait time. Planning-related minimum intervals are not used for wait times.
So that a wait time can be mapped, no overlapping can be defined for the operation. If a move time and a queue time have been defined for the operation in addition to a wait time, the system only ever takes into account the wait time. The wait time is also taken into account at the end of the operation.
In order integration without overlapping or flow manufacturing the wait time has, by definition, a higher priority than the move or queue time (see SAP Note 604878 ‑ R/3 -> APO: Relationship Durations with Interoperation Times and Overlapping).
Suboperations
Suboperations are mapped in SAP APO via a single start-start relationship from the main operation to the suboperation. This relationship is not scheduled and does not have a minimum interval.
In overlapping or flow manufacturing the suboperations are not taken into account. Relationships for overlapping or flow manufacturing are generated independently of the relationships for suboperations.
Product Interchangeability
See Product Interchangeability with Order Processing SAP R/3
Enhanced Integration of Reference Operation Sets
See
Enhanced Integration of Reference Operation
Sets