Purpose

This process describes a shop floor production or repetitive manufacturing scenario for an assembly produced in-house and its components.In SAP APO, you plan the assembly and the interchangeable components from the assembly.You use production process models (PPMs) or PP/DS runtime objects to plan products produced in-house.You procure the interchangeable components using in-house production or external procurement.When planning the components, the system takes account of the product interchangeability master data you created in SAP APO.You transfer the planned orders you create for the assembly in SAP APO as manufacturing orders or as planned orders to SAP R/3. You use SAP R/3:

To manage the master data (material masters, bills of material, routings, and so on)

To plan the components that are not relevant to SAP APO

To execute order processing (confirmation, goods movement, and so on)

In a repetitive manufacturing scenario, you can only execute the confirmation with reference to an order.Confirmation without reference to an order is not supported.

The essential features of the shop floor production or repetitive manufacturing scenarios are as follows:

You do not use any discontinuation data for the SAP APO relevant, interchangeable components in SAP R/3.

In SAP R/3, you can only create manufacturing orders for the assembly by transferring planned orders created in SAP APO (with the conversion indicator set) to SAP R/3 as manufacturing orders.

You only plan single substitutions in SAP APO.Therefore, you only create in-house production orders for the assembly that contain a maximum of one substitute item for an interchangeable component in addition to an original item.You cannot transfer an in-house production order with a multiple substitution to SAP R/3.

Prerequisites

In addition to the prerequisites that apply in general to production planning and production processing in an integrated scenario, the following prerequisites must be met in planning with product interchangeability:

You have transferred the master data (products and PPMs) and the transaction data (requirements and stock) for the SAP APO relevant assembly and the interchangeable components from SAP R/3 to SAP APO.

You have maintained the master data in SAP APO that is relevant for planning with product interchangeability.In particular, you have created the product interchangeability master data for the interchangeable components in SAP APO.(If required, you can transfer discontinuation data from SAP R/3 to SAP APO .)To avoid multiple substitutions in in-house production orders, you only use a supersession chain with two products (A – B) in SAP APO or update the bills of material for the sources of supply in SAP APO in time.For more information, see Correction of an Order with a Multiple Substitution .

You use SAP R/3 4.0B or a higher release to process manufacturing orders with substituted components.

Process Flow

You execute procurement planning for the assembly and the interchangeable components in SAP APO.In SAP APO, you execute a suitably defined production planning run with the MRP heuristic SAP_MRP_001 for these products.In the MRP run, the system creates planned orders for the assembly and thus dependent requirements for the components.To be able to forward requirements, stock, and fixed receipts for a discontinued component to a successor product, the system always automatically plans all products in a supersession chain in the MRP run.For requirements forwarding, it is not relevant if it is a dependent requirement, a planned independent requirement, or a customer requirement for the component.To forward requirements, stock, and fixed receipts, the system creates product substitution orders and automatically links them with the requirements being substituted using pegging relationships .

In the planning phase, product substitutions are modeled by the product substitution orders and the pegging relationships to the requirements to be substituted.In particular, the assembly planned orders only contain dependent requirements for the original components.Since you cannot transfer product substitution orders to SAP R/3, product substitutions are only visible in SAP APO and not in SAP R/3. Therefore, SAP R/3 displays a different planning situation in the planning phase to SAP APO.In SAP R/3, there are surpluses or shortages that relate to the product substitution orders that only exist in SAP APO.

PP/DS creates a planned order for an assembly with the discontinued component A.PP/DS forwards the requirement for component A to the valid successor component B by means of the product substitution order.Based on the product substitution order, PP/DS creates a planned order for the component B.You now transfer the assembly planned order and the planned order for the component B to SAP R/3. However, the direct pegged requirement for component B, the product substitution order, is not transferred to SAP R/3.The original pegged requirement, the assembly planned order, still does not contain a dependent requirement for the substitute component B in the planning phase. Therefore, the planned order for component B represents a surplus in SAP R/3.SAP R/3 identifies the dependent requirement for the discontinued component A as not sufficiently covered, even though the planned order for component B is intended to cover this requirement.

You execute additional planning steps in SAP APO in the production planning run or in interactive planning.These are used to:

Remove planning problems for the assembly and for the components (such as delays or shortages)

Execute sequencing on resources

To do this, you use various tools, such as PP/DS optimization, detailed scheduling heuristics, the PP heuristic for Rescheduling: Bottom-Up, or interactive planning.

In these planning steps, quantities and dates/times of the procurement proposals for the assembly and for the interchangeable components can change.As a result, the substitutions mapped using the product substitution orders may no longer be up-to-date.A change to the date/time can also violate the pegging interval between a dependent requirement and a product substitution order, meaning that the system deletes the dynamic pegging relationship, and the substitution information for the dependent requirement is lost.If you execute an MRP planning run again (see step 1), the system updates the product substitution orders.

If you have completed planning, you start the execution phase.The feature of this is that the substitute components have to be contained in the planned order or in the manufacturing order for the assembly.It is only then that the substitutions are also visible in SAP R/3.Therefore, it is necessary to update the dependent requirements in the assembly planned order.If you use manufacturing order processing in SAP R/3, you must set the conversion indicator for the planned orders in PP/DS.If you execute planned order processing in SAP R/3, you execute a suitably configured ATP check for the orders in PP/DS.

If you set the conversion indicator, the system updates the dependent requirements in the planned order, on the basis of the pegging relationships between a dependent requirement being substituted and the product substitution order.

If you perform an ATP check, the system updates the dependent requirements in the planned order, on the basis of the availability situation of the components in a supersession chain.

The system creates planning-relevant events for the change to the dependent requirements.In the standard system, the system reacts to the events by setting planning file entries for the components.The system reduces product substitution orders that are no longer required immediately or else in the next MRP planning run.

After the conversion indicator is set and after the ATP check, an order has the status firmed output .Therefore, you can still only change the order manually.

Start the execution phase shortly before the production start for the assembly.This is the only to make sure:

That the system can update planning automatically for as long as possible in the MRP planning run

That the components are not yet discontinued at the start of the execution phase and the dependent requirements correspond to the current availability situation

To update the components of an in-house production order after date/time and quantity changes, you execute another ATP check in PP/DS if required.This is possible for a manufacturing order until you release the manufacturing order.

You transfer the in-house production orders for the assembly and the interchangeable components to SAP R/3. (In the case of manufacturing orders, this can take place automatically and directly after the conversion indicator is set.)Since the in-house production order for the assembly contains the substitute components, the substitutions are now visible in SAP R/3.SAP APO and SAP R/3 display the same planning situation.

In SAP R/3, you plan the components of the assembly that are not relevant to SAP APO.

In SAP R/3, you can make various manual changes to an in-house production order for the assembly, such as quantity or date/time changes.

Since the product interchangeability master data is only known in SAP APO, SAP R/3 does not take account of this master data when an order is changed.

In general, the dependent requirement dates/times and quantities for an order no longer correspond to the availability situation of the components after a change is made.To check the availability of the components after an order change, you can also call an ATP check for an order in SAP R/3.The ATP check does not take account of any product interchangeability master data in SAP APO, and therefore does not update the components and dependent requirements for the order.Only the ATP check in PP/DS can do this.

For more information, see:

Manual Changes to an Order in SAP R/3

ATP Check in SAP R/3

You process the in-house production orders for the assembly and the components in SAP R/3 (confirmation, goods movement, and so on).The process for an in-house production order, which contains substitute components, does not differ from the process for a “normal” order.

If you technically complete a manufacturing order in SAP R/3, the manufacturing order is automatically deleted in SAP APO.If you reset the technical completion, the manufacturing order is created again automatically in SAP APO using the same components as before the technical completion.Therefore, any substitute components that the order may contain are not lost.