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IntroductiontoSAPPPPI

StudyMaterialContributedbyUlhasKavleSeniorSAP
Consultant



IntroductiontoSAPPPPISAPProcessManufacturing


IntroductiontoSAPPPPIProcessManufacturing


Mydefinitionto"Processmanufacturing"isthat,itisaformofanindustry
type, where the products once manufactured, cannot be easily dis
assembled. It is also really not possible to rework the illmanufactured end
products, back in to raw materials. For example products such as food
products,chemicals,medicine,Towels,Paper,Steeletc.

With the above definition of a process industry in prespective, SAP offers
SAPPPPIorSAPPIwhichcanbeusedtoimplementbusinessprocessesina
processindustry.

ThereareamanykeydifferencesbetweenProcessmanufacturingand
discretemanufacturingwithrespecttomanufacturingprocessesandSAP
offerings.

Speakingofthekeydifferences,thefollowingpointsareslatedhere
andexplainedinthenextsectionbelow:

AMasterRecipeisoneofthekeydifferencesandallthe
individualdifferencesrevolvearoundthemasterrecipe.SAP
PPPIhasatasklistcalledasaMasterRecipevisavisthe
routingsintheSAPPP.SAPusesthemasterrecipewhen
creatingtheprocessorder.ThepurposeRoutingsandthe
MasterRecipeisequaltoalargeextent,likescheduling,
capacitygenerations,generatingplannedcostsandcomponent
scheduling.Thoughthemajordifferencebetweenthemaster
recipeandtheroutingisa)embeddingoftheBOMinthetask
listthroughtheuseofproductionversions,b)materialquantity
calculations,c)processmanagementwhichdefinesastandard

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interfacebetweenSAPandtheshopfloortocommunicate
productionandexecutiondata.
ProcessManagementallowinganinterfacebetwenSAPandthe
shopfloordestinations.
Processorderrelateddocumentation.





KeyDifferencesbetweenSAPPPPIProcessManufacturing&
SAPPPDiscreteManufacturing:


AdetailedanalysisofthesedifferenceismadeallovertheSAPPPPI
Documentation.Thoughastartismadehereinthissectiontobring
aboutthedifferencesclearlybeforedeepdivingintothearticlein
subsequentpages.ThedifferencebetwenSAPPPandPPPIismade
onlyasanoverview:


a)ProductionVersionsandtheiruseinMasterRecipe


Visvistheroutingorraterouting,themasterrecipecollectsthe
operationsandtheBOMtogetherinonemasterdatathroughtheuse
ofproductionversion.Theproductionversionisexplodedintherecipe
topullinthematerialBOM.

BringingtheBOMinsidethetasklisthelpsingeneratingonemore
uniquefeatureofarecipecalledtheMaterialQuantityCalculations.
Thematerialquantitycalculationshelpstochangethecomponent
quantitiesandtheheadermaterialquantityvisviseachotherand
withrespecttothevaluesoftheactiveingredients(batch
classificationspecifications)ofthecomponentsandtheheader
material.

Beforecreatingtherecipe,oneshouldhaveaProductionversion
createdwithatleasttheBOMembeddedinit,whichwillhelpadding
theBOMtotherecipe.


VeryImportantNoteItseemstobeanormalpracticethatthe
recipegroupnumberisaddedtotheproductionversionafteritis
created.Soyoumayhavetomaintaintheproductionversion
information,firstlyaftertheBOMcreationandbeforetherecipe
creationandonceaftertherecipecreationsoastoassigntheRecipe
groupnumbertoit.



b)Theconceptofphasesandoperationsinatasklist

Amasterrecipecarriesaconceptofoperationsassignedwith
phasesvisvisdiscretemanufacturingwhichhasonly
operationleveldetails.Theoperationsarethusmereplace

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holdersofphasesandcarrynomajorimportanceinSAPPPPI.

Theintroductionofphaseshelpstheorganizationtobreakdown
theactivitiesonanoperation(asphases)anddetailthemout.
Thestandardvalues/activitieslikethesetuptimeordurationor
machinetimeetcareassignedtothephasesinprocess
manufacturingunlikediscretemanufacturingwheretheyare
assignedtotheoperationitself.Thistakesyoutoanobvious
conclusionthattheconfirmationinprocessmanufacturingare
carriedoutatthephaselevelratherthanatoperationlevel.
TheconceptofRelationshipsbetweenphasesofdifferent
operationsorwiththesameoperationorevenbetweentwo
differentmaterialrecipeshelpsinschedulingtheprocessorders
(aspertherelationssetup).Therelationshipbetweenphases
inSAPPPPIcanbecorrelatedwithparallelandalternate
operationsequencesetupindiscretemanufacturing.
TheExternaloperationprocessingisalsocarriedoutatthe
phaselevelandnotattheoperationlevel.
Thoughonecanassigninspectioncharacteristicstoboth
operationsandphases.
Even the components of the BOM in SAP PPPI, are assigned to the
phases and not the operations, thus strengthening the fact that the
phasesgovernovertheoperations.
Theworkcenterorresourceareassignedtotheoperationlevelandall
thephasesassignedtotheoperationusesthesameresource.Aresource
carries a QDR system, which is the address of an external control
systemtowhichdatahastobesent,incaseswhenthecontrolrecipe
destination is an external process control system. The QDR field can
beconfiguredinSAP.
The set up of the "process management functionality in SAP PP PI"
through control recipe destination, process instruction categories and
processmessagecategoriesisdoneatthephaselevel.Youcanassigna
unique control recipe destination to a phase and a set of process
instruction categories which are eventually downloaded to the
respective destinations as control recipe. This is explained in detail
furtherdown.



c)TheconceptofMateriallistandMaterialQuantityCalculations
intheMasterRecipe

Asdiscussedintheaboveparagraphthemasterrecipehasanadded
capabilitytobringinthemateriallistortheBOMthroughtheuseof
productionversions.ThepresenceofBOMintherecipeallowsSAP
PPPItoaddafunctionalitycalledas"materialquantitycalculations"
fortheheadermaterialaswellasthecomponents,whereinyoucan
changethecomponentquantitiesandtheheadermaterialquantities
basedonthecharacteristicsvaluesoftheirrespectivebatchclasses
andthroughformulaswrittenasmacros.

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d)ProcessManagement


Themasterrecipealsocomeswithafeaturecalledastheprocess
management,whichisprimarydifferentiatorbetweentheRoutingand
theRecipe.

Thisfeaturesallowsaclearcommunicationorinterfacebetween
SAPandtheshopfloordestinationtocommunicateproduction
orexecutionrelateddatabetweenthem.Thisinterfaceisa
standardSAPdefinedinterfaceandworkswithSAPsending
processinstructioncategoriestothedestinationandthe
destinationsendingbackexecutiondatatoSAPforupdationin
SAPdatabase.
Everyphaseinamasterrecipehasashopfloordestinationor
controlrecipedestination.Theprocessinstructionsareassigned
tothephasestheseprocessinstructionscarryprocessnotes,
orderdetails,phasedetails,componentdetails,quality
inspectiondetails,goodsreceiptdetails.Theprocess
instructionsarebundledupintoacontrolrecipeandaresentto
thecontrolrecipedestination,whichoncesenttotheshopfloor
operatorortheprocesscontrolsystem,helpsthemtowiththe
detailedinformationandinstructionsabouttheorderand
initiatesatriggertostartmanufacturingactivities.
Theprocessinstructionsalsocontainsinformationonthe
ProcessmessageswhicharesupposedtobesentbacktoSAP
(datarequests),liketheconfirmationrecordsfortheorder
goodsissuerecordsfortheorderandgoodsreceiptsdatafor
theorder,inspectionresultsforthereceivedgoodsetc.
EventuallytheprocessesmessagespostthedatainSAPtables
usingvariousBAPIsandfunctionalmodules.
Anindividualprocessinstructionforexampleaprocess
instructionfororderinformation,containscharacteristicslikethe
ordernumber,plantcode,ordertype,orderstartdate,order
finishdate,orderreservationnumber,headerbatchnumber(if
any)etc.Thesecharacteristicscarrytherespectivevalues.You
canmanuallychange/addthevaluesorhavethempopulatedby
thesystem(forexampleforcharacteristicslikeordernumber,
orderstartdate,ordertypeetc)aspertheprocessdesign.The
characteristicsusedinprocessinstructionstocarryvaluesof
variousparametersarealwaysassignedwithacharacteristics
groupcalledasPPPI_INST.
Theprocessinstructionscanbeassignedtothemasterrecipe
withproductorprocessspecificvaluesassignedinthemorthey
canbeassignedtothecontrolrecipedestinationitself.
Assigningtheprocessinstructionsatthecontrolrecipe
destinationwouldautomaticallyexplodethemintheprocess
orderandthisavoidstheeffortofindividuallyassigningthemat
thematerial/plantlevelmasterrecipes.Forprocessinstruction
attachedtothedestination,youcouldstillassignvaluestothem
buttheywouldnotbematerialspecificandwouldbevery
genericinnaturewhichisapplicabletotheprocessescarried
outatthedestination.
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TheProcessinstructionsarebundledupinacontrolrecipe
whichisdownloadedfromSAPandsentthecontrolsystemor
theshopflooroperator.TheRecipientprocessestheprocess
orderandsendsactivitycompletionprocessmessagestothe
SAPsystemintheformofprocessmessages.
CorrelationOnecancorrelatetheprocessinstructionsasan
examinationQuestionPapersetforaparticulargradewith
instructionsandquestionsinit.Thisquestionpaper(asprocess
instructions)isgiventoeachandeverystudentbelongingtoa
particulargrade(agradecanbeacontrolRecipedestination)
alongwiththeprocessmessagerequesttoanswerthe
questionsinaparticularsettime(considerthefilledupanswer
sheetalongwiththeRollnumberandgradeasprocess
messageswhicharerequestedbackbythesystem).The
studentsareexpectedtocarryouttheactivitiesofanswering
andappearingforthetestandinreturnsubmittheanswersheet
asprocessmessagebacktotheexaminer(theexaminercanbe
theSAPsystemwhichupdatesthecompletioninformationand
marksinSAPsystem).
StandardSAPinSAPPPPIisdesignedtohavetherecipientas
ashopflooroperatorinSAPitself,whocompletestheorder
detailingandmanufacturinginPISHEETSandsendsbackthe
processmessagestotheSAPcockpitstoprocessstandard
designedBAPIs.Ontheotherhandiftherecipientisaprocess
controlsystemoutsideofSAP,hecanalsoreceiveorrequest
theinstructionsinacontrolrecipetoaidinproductionandsend
backthemessagestoSAPsystemthroughstandardinterfaces
designedforsuchintegrationsbetweenSAPandtheexternal
shopfloorcontrolsystem.

Figure1




e)UseofIntraMaterialsinSAPPPPI


Use of Intra Materials in a key feature available both in process
manufacturinganddiscretemanufacturingthoughitispredominantlytalked
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about in process manufacturing since SAP PPPI offers storage resources in

betweenoperationstostoretheseintramaterials.IntraMaterialsarematerials
which are added to stock in between production and removed from stock
whentheyareissuedtothenextresource.




f)ElectronicBatchRecord:


SAPPPPIprovidesaFacilityfordocumentation&OpticalArchivingofthe
Batch Related data of a process order or order related data for future
references. You can document or record all the process order related
activitiesoftheprocessorder.

ControlRecipeDestinations

ControlrecipeDestinations


StandardSAPhascontrolrecipedestinationswhichreceivethe
processinstructionsandusingwhichthedestinationcarriesoutthe
manufacturingandattheendofwhichtheysendbacktheprocess
messagestoconfirmtheirproductionactivitiesorproductionstatuson
arealtimebasis.

Thecontrolrecipedestinationsareassignedtotheindividualphases
ofanoperationwhichmeansthateveryphaseinamasterrecipecan
carrydifferentcontrolrecipedestinations.Onecontrolrecipeis
createdforagivendestinationandordercombination.

ThedestinationsorrecipientsoftheprocessinstructionscanbeSAP
destinationsorexternalprocesscontrolsystemdestinations.Ifthe
destinationisinSAPitself,thenitcanbeashopfloor
operator/operatorgroupataplantoraproductionlineorshopfloor
operator/operatorgroupforaspecificactivity,executingthephase
whereasifthedestinationisanexternalprocesscontrolsystem
outsideofSAP,thentheprocessinstructions&processmessagesare
interfacedwiththatexternalsystem.

Thedefinitionofthecontrolrecipedestinationneedsconfiguringthe
destinationtype,addressofthedestination(inexternalsystem,the
addressistheRFCdestinationoftheprocesscontrolsystems).


ControlRecipe SAP ExternalControlSystem
Destination

1&4 DestinationliesinSAP
ERPsystem

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2&3 DestinationsliesoutsideofSAP
ERPsystemandiscalledasan
ExternalControlSystem




ControlRecipeDestinationsType1&4Destinationlocatedin
SAPECCSystem


ForshopfloordestinationswhichareinSAPitself,thereare2
differenttypesofdestinationscalled1and4,torepresentthem.
Thedestinationoperatorgroupoftype1receivesalltheprocess
instructions&requestedprocessmessageswellarrangedonan
ABAPbasedsheetorscreencalledasaPISheet(oneforanorder,
foradestination).Whereasforadestinationoftype4,asheet
containingalltheprocessinstructionsandrequestingprocess
messages,wellarrangedonawebbasedsheetbrowserbasedPI
Sheetissenttotheinternaloperator/operatorgroup.


Note:AnABAPbasedPISHEETisshownbelow,ifthesameissetfor
adestinationtype4browserbasedPISheet,thenthesheetwith
theinformationwouldappearinabrowserinHTMLformat.With
DestinationtypetherearestandardBAPIsandconnectionsworking,
whichwouldprocessthemessagesoncesentbacktoSAPbythe
respectivedestinations.


Note:Inconfigurationforthedestinationsoftype2and3,youcan
assignprocessinstructionswhichwouldbeautomaticallybecomea
partofcontrolrecipeandwouldbedownloadedtotheexternalcontrol
system.Whereasfordestinationsoftype1and4,thereisaprovision
toassigntheprocessinstructionsinasequence(makingalistof
suitableinstructions)whicharegeneratedintheprocessordercontrol
recipeandsubsequentlydownloadedtotheSAPoperator/operator
group.

Note:TransactiontocreatetheControlRecipedestinationisO10C.


ABAPBasedPISHEET

OrderInformaon

Processordernumber 10002569
Processordertype PI01
Plant 0002
ProcessorderQuanty 10
ControlRecipenumber 100000000029823
ReservaonNumber 561543
Desnaon 01ShopPlant0002
Date/Time 25thDec2010

Operaon/PhaseInformaon

Operaon Phase Descripon Standard StartDate&Time FinishDate

Valuesforthe &Time
order

0010 0011 2HR 25.12.201012:45:00 25.12.2010

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14:45:00

0010 0012 1HR 25.12.201014:45:00 25.12.2010

15:45:00

0020 0014 0.5HR 25.12.201015:45:00 25.12.2010

16:15:00

ComponentInformaon

Operaon Phase Component Descripon Qty UOM SLOC

0010 0011 C1 C1 10 EA RM

0010 0012 C2 C2 20 EA RM

0020 0014 C3 C3 10 EA RM

RequesngPhaseConrmaons

Operaon Phase Yield Scrap SetupTime Machine Text

Time

RequesngGoodsIssues

Component Qty UOM SLOC Batch Component Text

Descripon

C1 C1

C2 C2

C3 C3

RequesngGoodsReceipts

DynamicFunconCallforMIGO_GRTransaconCodePressheretoaccessMB31Tcode

ControlRecipeDestinationsType2&3Destinationoutsideof
SAP(ExternalSystems)


ForcontrolrecipedestinationslyingoutsideoftheSAPsystem,i.e.,
externalprocesscontrolsystemsormanufacturingexecutionsystems
lyingoutsideofSAP,theprocessinstructionsaresenttheirthrougha
standarddesignedinterface.Therearemajorlytwocontrolrecipe
destinationsinteractingwithexternalprocesscontrolsystems,namely
2and3.

Destinationtype2isusedwhentheSAPinitiatesthetransferor
downloadofcontrolrecipetotheexternalprocesscontrolsystem
(Pushcase)whereas3isusedwhenthetransferordownloadof
controlrecipeistriggeredbytheexternalcontrolsystem(Pullcase).

NoteWhentheprocesscontrolsystemisanexternalsystem,you
canassigntheprocessinstructioncategoriesandhavethesystem
generatecontrolrecipesautomatically.

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Note:Inconfigurationforthedestinationsoftype2and3,youcan
assignprocessinstructionswhichwouldbeautomaticallybecomea
partofcontrolrecipeandwouldbedownloadedtotheexternalcontrol
system.Whereasfordestinationsoftype1and4,thereisaprovision
toassigntheprocessinstructionsinasequence(makingalistof
suitableinstructions)whicharegeneratedintheprocessordercontrol
recipeandsubsequentlydownloadedtotheSAPoperator/operator
group.

NoteForexternalcontrolsystems,itisrequiredtodefineaRFC
destination,soastodefinetheconnectionstothecontrolsystemand
enableSAPtocommunicatewiththesystem.Thetransactioncodeto
createisSM59.

Figure2

Figure3




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