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VERSION: 00 REVISION: 00
AUTHOR
REVIEW
YANICK GAUTHIER
APPROVAL
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Document History
Paragraph # Change
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Table of Contents
1. Introduction........................................................................................................................ 5
1.1 Reference Documents............................................................................................. 5
1.2 Definitions & Acronyms...........................................................................................5
2. Document Purpose.......................................................................................................... 6
3. Short Functional Description.......................................................................................... 6
3.1 MFG05-01_Process Order confirmation (Time Declaration).................................6
3.2 MFG05-02_Process Order Closure.........................................................................7
3.3 MFG08-01_Reporting...............................................................................................7
4. Business Process Flow Chart........................................................................................ 9
5. Solution.......................................................................................................................... 10
5.1 MFG05-01_Process Order confirmation (Time Declaration)...............................10
5.2 MFG05-02_Process Order Closure.......................................................................16
5.3 MFG08-01_Reporting............................................................................................. 19
5.4 Functional Message Codes & Content.................................................................22
6. Overview Of SAP Transactions & Customizing Activities..........................................23
6.1 SAP Transactions................................................................................................... 23
6.2 Customizing Activities........................................................................................... 23
7. Overview of Additional Developments.........................................................................30
7.1 Reports, Forms....................................................................................................... 30
7.2 Interfaces................................................................................................................ 30
7.3 Conversions........................................................................................................... 30
7.4 Enhancements.......................................................................................................... 30
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1. INTRODUCTION
1.1 REFERENCE DOCUMENTS
Reference Document
Term/Acronyms Definition/Explanation
BoM Bill of Material; it is a complete, formally structured list of the components that make up a
product or assembly. The list contains the material number of each component, together
with the quantity and unit of measure.
ECM Engineering change management; it is an Engineering change document which is used for
BOM and recipe creation and changes.
FP Finished product; this term describes both the end product manufactured.
PO Process Order; it is the main control instrument used in production. It is used to describe,
update and monitor all production-relevant factors, both planned and actual.
QA Quality Assurance
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2. DOCUMENT PURPOSE
The purpose of this document is to describe how the solution will respond to user
requirements concerning Manufacturing Organizational Structure.
For each of the above sub-processes, the following entities are in scope:
Process Orders confirmation is done at the end of production activities at operation level. It is
possible to manage both partial and final confirmation.
During process order confirmation operator is able to close open reservations, if needed.
Note: if any error occurs during process order confirmation, the operator can reverse the
process.
In EZEM, the operator declares actual values for labour and machine time, at operation level,
at the end of process order processing.
In ACIST time declaration is not performed and the user always confirms standard values (if
defined in the master recipe) for labour times 1, at operation level, at the end of process order
processing. Time reconciliation is done on monthly basis, considering overall production
outcomes and production operator timesheets.
1
Machine time is not relevant for ACIST.
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Process order is closed after completing and verifying production operations. In particular,
production department checks that all the following are verified before closing a Process
Order:
During reconciliation process user can inquiry all the inventory movements related to a
specific Process Order (goods receipt for process order, goods issue against process order,
reversal of movements).
Note: User can only cancel a Process Order that is released but not yet in production.
Final Process Order closure (technical completion) corresponds to the “logistic closure” of the
Process Order. When technical completion is posted, no more inventory posting is allowed.
Only finance department can revoke process order technical completion, if needed.
It is possible to close released Process order at any time, even after the start of production
but it is possible to cancel Process Orders only if they are not yet in production.
3.3 MFG08-01_REPORTING
Reporting is the method to analyze the performance of the system: it consists in querying the
system for obtaining partial (filtered by same particular criteria) or complete information
about the data contained in it.
In the following are explained the different investigations that are possible to do over the
system.
order status;
range of dates;
product number.
User is able to inquiry, for a process order, the details of confirmation data. For example, it is
possible to explore the details of actual values, confirmed quantity, confirmation type (if
partial or final), etc…
User is able to inquiry, for a process order, the details of the following material movement
posting:
material consumption;
material consumption reversal;
product goods receipt;
product goods receipt reversal.
Furthermore, it is always possible for the user to examine the details of goods movement
errors generated during material movement posting.
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It is also possible for the user to investigate for a Process Order the details of:
order status;
operation status;
phase status.
At Process Order Release the details of missing parts due to inventory shortfall. User is able
to inquiry the list of all components batch/lot numbers and quantity used to produce the
specific Product batch/Process Order starting by:
It is possible to report finished product process orders for which half-finished product
batch/lot number has been allocated as well as those for which half-finished product batch/lot
number is not allocated.
It is possible to report the list of restricted batches/lots allocated to a process order and the
reason for batch/lot restrictions at any point of time.
User is able to inquiry at any moment which production version has been used to produce a
specific production batch/lot.
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5. SOLUTION
5.1 MFG05-01_PROCESS ORDER CONFIRMATION (TIME DECLARATION)
Line No. Description of solution with Business process step number T.Code Cust. No Dev. No URS Reference
Acist Asia
Acist US
Acist EU
Ezem
BDI
UNITY-FSP- Process Order Confirmation – Milestone Confirmation COR6 003 MFG05-01_0010
MFG-04-0010
Confirmation of a process order is done at phase level through transaction COR6 or CORR MFG05-01_0020
CORR for collective entry. Nevertheless, in order to reduce the amount of
confirmation it is possible to set a milestone confirmation that will automatically
X X X X
confirmed the previous phases not already confirmed. This setting allows to manage
confirmation at operation level.
The system is set so that no successor milestone confirmation can be done in the
system without a previous milestone confirmation is confirmed.
UNITY-FSP- Steps 2a-3: Process Order Confirmation – Single Order Confirmation COR6 003 MFG05-01_0010
MFG-04-0020
User is able to proceed with process order confirmation (single confirmation) MFG05-01_0020
launching transaction COR6 and inserting the following parameters:
Process Order
Operation/Phase* X X X X
(*) if not inserted is automatically selected by the system if only phase for the order
requires confirmation, or manually selected by the user based on the list of phases
requiring confirmation displayed by the user.
After the insertion of selection parameters, clicking on “Enter” the system displays
the “Process Order Confirmation Create: Detail” screen.
UNITY-FSP- Step 2b: Process Order Confirmation – Collective Order Confirmation CORR 003 MFG05-01_0010 X X X X
MFG-04-0030
User is able to proceed with multiple process order confirmation (multiple MFG05-01_0020
confirmation) launching transaction CORR and selecting one of the following screen
options:
Confirmation view;
Process Order view (preferred).
In case of “Confirmation view” the user has to insert the following selection
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parameters for all the orders requiring confirmation:
Confirmation number.
In case of “Process Order view” the user has to insert the following selection
parameters for all the orders requiring confirmation:
Process Order;
Phase/Operation.
After the insertion of selection parameters, clicking on “Enter” the system
automatically set the following information into the “Collective Entry: Time Ticket”
screen:
In case of “Confirmation view”:
o Process Order;
o Operation/Phase;
o Posting Date;
o Resource;
o Plant.
o Posting Date;
o Resource;
o Plant.
UNITY-FSP- Steps 4-5-6: Process Order Confirmation – Confirmation Data Insertion COR6 003 MFG05-01_0010 X X X X
MFG-04-0040
During process order confirmation, in both the scenarios, following main information CORR MFG05-01_0020
have to be specified by the user:
Confirmation Type: as per options specified in line 0010;
Yield: actual produced quantity which confirmation data are referring to;
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Activities: labour/machine actual/standard times to confirm.
UNITY-FSP- Step 4: Process Order Confirmation – Confirmation Type COR6 003 MFG05-01_0030
MFG-04-0050
Process Order confirmation is done at phase level through transaction COR6 or CORR CORR
for collective entry. Three different confirmation type are allowed in the system:
- Automatic final confirmation: The system set automatically the final
confirmation while the Yield confirm at phase level is equal or above the
yield expected. If the yield confirmed is lower than the quantity expected,
the system set automatically the flag partial confirmation.
- Final Confirmation: The user can declare a final confirmation, especially
X X X X
in the case of actual yield is lower than the yield expected. The system is
not waiting for any further confirmation.
- Partial confirmation: The user can state that the confirmation done at
phase level is partial; therefore the system is expecting further
confirmation.
For all order types (ZNOR, ZSTA, ZCLI, ZENG, ZREW, ZVAL), by default, transaction
COR6 is set for confirmation type: “Automatic final confirmation”.
UNITY-FSP- Step 6: Process Order Confirmation – Activity confirmation at phase level COR6 003 MFG05-01_0010
MFG-04-0060
The system allows the user to insert actual values of activities (e.g. labor hour, CORR MFG05-01_0020
machine hour, etc.) before the process order is technically complete or closed. Zero
is an acceptable labor time. This action is possible through transaction COR6 or
CORR. The possible values that can be confirmed at each phase can be: X X X X
standard values: associated to the resource in the specific couple
phase/process order;
actual values: inserted by the user based on the actual use of machine
and operators involved in the production process.
UNITY-FSP- Step 6: Process Order Confirmation – Activity confirmation at phase level COR6 MFG05-01_0010 X X X X
MFG-04-0070
When user accesses to COR6 for a couple process order-phase, the system does not MFG05-01_0020
populate automatically fields “Yield” and “Time for activities” until the user:
Enter manually any value in those fields
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or
Push the button “Actual data” to automatically retrieve default values
UNITY-FSP- Step 6: Process Order Confirmation – Activity confirmation at phase level COR6 003 MFG05-01_0010
MFG-04-0080
In the “Process Order Confirmation Create: Detail” screen user has available, in field MFG05-01_0020
for Yield, Scrap and Activities time, the following columns:
MFG05-01_0030
“Confirmed to date”: which shows the quantity (quantity/time) already X X X X
confirmed for that phase
“Planned to be confirmed”: which shows the total quantity/time that is
expected to be confirmed (by default values)
UNITY-FSP- Step 6: Process Order Confirmation – Activity confirmation at phase level COR6 003 MFG05-01_0010
MFG-04-0090
The system retrieves the standard activities quantity based on the standard CORR MFG05-01_0020
time/yield of the phase confirmation while performing the actual confirmation. If no
modification is done by the user, while saving the confirmation the user back-flushes
the standard quantity of activities.
Otherwise in case of value modification according to actual values the system X X X X
records values inserted by the user.
During activity confirmation the user is able to insert comments using “Long Text”
button in the confirmation main screen. Text inserted by the user is than visible,
after confirmation, at any moment accessing in display modality to the confirmation
data.
UNITY-FSP- Step 8: Process Order Confirmation – Partial Confirmation COR6 003 MFG05-01_0030
MFG-04-0100
The system allows a partial confirmation of an order (partial confirmation of good CORR X X X X
issue and activity or a partial delivery of good receipt of a process order). It is
possible to right away confirm the next scheduled process order.
UNITY-FSP- Step 7: Process Order Confirmation – Over/Underdelivery Tolerances COR6 003 INV03-03_0060 X X X X
MFG-04-0110
During process order confirmation automatic checks are performed against: CORR INV03-03_0110
Overdelivery tolerance: Two parameters can be checked regarding
overdelivery:
o Yield overdelivery at phase level– yield overdelivery is driven by:
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The % in the field “Overdelivery tolerance” in work
scheduling view of the material master data
A customizing point referring to check of overdelivery
(no check, warning message or error message). Order
type/plant has been set to overdelivery above % in
work scheduling view gives an error message.
o Good Receipt overdelivery
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customizing.
Note: underdelivery is checked only at final confirmation and not at partial
confirmation of a phase.
UNITY-FSP- Process Order Confirmation – Confirmation data display CORT 003 MFG05-01_0030
MFG-04-0125
At any moment user is able to display confirmation data using transaction CORT and
inserting the following parameters:
Process Order
Operation/Phase (optional) X X X X
After the insertion of selection parameters, clicking on “Enter” the system displays
the “Display Process Order Confirmation: Operation/Overview” screen. Selecting the
confirmation to display (checkbox) and clicking on button “Details” the user is able to
display all confirmation data previously specified during phase confirmation
(comments included).
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UNITY-FSP- Process Order Closure – Reconciliation Activities COOISPI MFG05-02_0010
MFG-04-0130
While all quantities have been confirmed in a process order, it is possible to have a MFG08-01_0010
recap of all the quantities planned vs actual quantities so that the manufacturing
area can identify the reasons for variances. MFG08-01_0020
For example, this can be done using report transaction COOISPI where: MFG08-01_0050
o Operations
o Confirmations
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issue, whereas there was enough physical stock since
manufacturing has been performed normally on the shopfloor
For category 1 type of error, the user should correct the error in foreground, i.e.
before saving the good issue/good receipt.
For category 2 type of error, the user should double check its entry and if all is
according to physical manufacturing events, the user should save the confirmation
without correcting the error.
The error is then recording in SAP in transaction COGI, no posting is done in SAP of
partial quantity. This log of error should be reprocessed every day in order to have
correct stock inventory.
UNITY-FSP- Steps 11-12-13: Process Order Closure – Technical Completion COR1 001 MFG05-02_0020
MFG-04-0140
A process order has to be “Technically Closed (TECO)” by the user while: COR2 002
All confirmations have been done in the system. This will have to be COHVPI
checked manually by the user using a procedure, since there is no system
check.
Consumption of components are within pre-defined tolerances. This will
have to be checked manually by the user using a procedure, since there is
no system check.
There is no processing error of goods movements in the system relative to X X X X
the process order. The system does not allow the technical closure of an
order if for example processing error of goods movements remains or the
inspection lot is not yet completed.
The technical closure can be done order by order through the transaction
creation/change of a process order COR1/COR2 and in mass through transaction
COHVPI.
Note: in order to track over/under consumption of components, a procedure should
be put in place in order to check potential differences planned/actual and inform the
manufacturer.
UNITY-FSP- Steps 11-12-13: Process Order Closure – Technical Completion COR2 001 MFG05-02_0060 X X X X
MFG-04-0150
In order to make changes to a process order that has not been yet processed by 002
controlling, it is necessary to re-open the order. For that purpose, user has to open
the process order in change modality (COR2) and from the toolbar has to select the
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path “functions > restrict processing > Technically Complete”.
UNITY-FSP- Steps 11-12-13: Process Order Closure – Order Forced Completion COR1 001 MFG05-02_0040
MFG-04-0160
If an order should not be executed on the shop floor, the process order should be COR2 002 MFG05-02_0050
closed in order to:
Suppress the process order form the expected process order to be planned
Suppress the order reservation on the component quantities
X X X X
Suppress the capacity reservation on the resources.
Note that it is possible to close an order released:
But not yet in production
After the start of production if no error of goods movements is linked to
the process order and the inspection lot is not yet performed.
UNITY-FSP- Process Order Closure – Technical Completion Reversal COR2 001 MFG05-02_0070
MFG-04-0190
Only authorized users are allowed to revoke order technical completion. For that 002
purpose, user has to open the process order in change modality (COR2) and from X X X X
the toolbar has to select the path “functions > restrict processing > Revoke
Technically Complete”.
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5.3 MFG08-01_REPORTING
Line No. Description of solution with Business process step number T.Code Cust. No Dev. No URS Reference
Acist Asia
Acist US
Acist EU
Ezem
BDI
UNITY-FSP- Manufacturing Reporting – Process Order Information System COOISPI MFG05-02_0010
MFG-04-0200 The main reporting used in manufacturing is available thanks to the T.code: MFG08-01_0010
‘COOISPI’ “Process Order Information System”.
MFG08-01_0040
User can view all the orders in the system, including the orders with deletion flags or MFG08-01_0050
deletion indicators. Archived orders are not taken into account. The order
information system has the following display options: MFG08-01_0060
In an individual object list, a list is generated for the selected object (for X X X X
MFG08-01_0080
instance, order header, operation and component). User can define the
structure and appearance of the individual object list with a layout.
On the object overview the individual orders are displayed with their
subordinate objects in a hierarchical structure. With an overall profile, you
can define which fields are displayed and which objects (order headers,
items, sequences, and so on) are read or displayed. In addition, user can
define which fields are displayed for the individual objects.
UNITY-FSP- Manufacturing Reporting – Errors log on Process Order creation/release COR2 MFG08-01_0070
MFG-04-0210 Reason for failures in case of creation and release of process order can be checked COR3 MFG08-01_0090 X X X X
directly in the process order with the T.Code “COR2” or “COR3” and selecting from
the toolbar the path: ‘ GoTo -> Logs’ and selecting the appropriate step of the
process.
UNITY-FSP- Manufacturing Reporting – Single-level Bill of Materials Display CS11 MFG01-01_0110 X X X X
MFG-04-0220 User is able to inquiry Single-level BoM launching transaction CS11 and inserting the
following selection parameters:
Material;
Plant;
Alternative BoM (mandatory if required qty not inserted);
BoM application;
Valid From (date);
Change number (optional);
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Required qty (mandatory if required qty not inserted).
The system provides a report which provides for a given HFP/FP, for specified time
period time, the valid BOMs with a list of data related to components. In case of
finished product the system is providing also the details about the following levels
(HFG Bill of Material).
In the first screen, the change number can be defined by the user. The date from
which change is effective can be displayed in the layout.
UNITY-FSP- Manufacturing Reporting – Where used List (Material) Display CS15 MFG01-01_0070 X X X X
MFG-04-0240
User is able to inquiry all Bill of Materials where a specific component is used MFG01-01_0110
launching transaction CS15 and inserting the following selection parameters:
MFG01-01_0130
Material;
Type of where used’ list (Direct / Using classes);
Valid from/to (date);
Required qty;
Plant;
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Item category;
Usage.
The system provides a report that shows all the products (with details of BoM
alternative and item) where the selected material is used into.
UNITY-FSP- Manufacturing Reporting – Display Batch/Lot used Production Version COR3 MFG08-01_0100
MFG-04-0250
User is able to see which Production Version is used to produce a specific production
batch/lot launching transaction COR3 and displaying the Mast. Data view in the PO X X X X
header. In the Production Version tab it is possible to know the Production Version
used as well as the BOM explosion date.
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001 Define Authorization Key for User Status Profile(BS52) SPRO/Production planning for process
industries/Process order/Master
data/Order/Define Authorization Key
for User Status Profile(BS52)
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7.2 INTERFACES
7.3 CONVERSIONS
7.4 ENHANCEMENTS
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