SAP PPPI Process orders

Study Material Contributed by Ulhas Kavle - Senior SAP Consultant, Mahindra Satyam

SAP PPPI Process Order Creation

Creation of Process order

The process orders in SAP PPPI are very much similar to production orders in SAP PP. The only difference which is visibly seen is the play of the master recipe in process orders bringing in concepts such as material quantity calculations, process instructions. When the process order is released, the system allows the creation of the control recipe for the bundling up the process instruction categories for a given control recipe destination.

You can configure the point of creation of the control recipe – i.e., at orders creation or at order release using the production scheduler profile (transaction code CORY). The below screen shot for the production scheduler profile is a cropped image which only shows the “automatic action” section which is worth mentioning for SAP PPPI.

Figure 48

SAP PPPI Process Order Creation

Contribution of the Settings done in Order Type Dependent Parameter for Process Order

It would also be worth mentioning the configuration involved in order type dependent parameters required for creation of the process order. Here we would only be looking at settings especially available for configuration in SAP Process industry vis-à-vis what we have in SAP production planning. The below screen shot shows the evident different (as seen in the first tab of the order type dependent parameters settings); rest of the tabs are pretty much same and are already explained the SAP PP – Production planning for discrete manufacturing section. The transaction code COR4 is used to configure the order type dependent parameter for SAP process industry manufacturing.

a) Options for selection of automatic and manual selection of the production versions are seen on the screen.

b) Checking component details along with checking of the operation details is another option available. The checking of the component details when it is brought in to the process order is possible.

c) Release of the orders after an approval is granted is an option available in SAP PPPI. This can be configured for the order through the selection of the indicator – “Approval required”.

d) Master recipe selection process can be also be configured, whether the selection is optional or mandatory and whether it is automatic or manual.

e) One can also set the perspective in which the phase relationships should be displayed, i.e., whether as predecessor or successor or both mixed or as created in the order. In other words, when you go route yourself into phase relationship in a process order, you can set an option to display a successor to a phase that you have chosen or to display a predecessor to a phase that you have chosen or whether you want to display both successor & predecessor to the phase that you have selected (the mixed option).

Let’s say that you have selected phase 10, 20 and 30 and pressed the phase relationship option to view their relationship and if you have chosen the “predecessor” option here, then for phase 10, it will not show any predecessor phase, but for phase 20, it will show phase 10 as predecessor and for phase 30, it will show 20 as the predecessor phase.

f) The selection ID helps you to select the selection priority list for selection of the master recipe.

g) There are 3 settings for the process data documentation specifying whether you want process data documentation or not. This is only used in SAP PPPI. The process data documentation enables you to create a list of quality relevant data and store it in optical archive. You can archive either “order data records” or “batch records”. The settings define whether you want to use the “order records” i.e., it contains all the process related quality relevant data that is collected around a process order or you want to use “batch records” i.e., it contains all the process related quality relevant data upon the production of a batch. The batch records comply with the guidelines on goods manufacturing practices (GMP) for pharmaceutical and food processing industries. Here the production related information is stored/archived.

Figure 49

Creating a Process Order

Creating a Process Order in SAP PPPI

Following are some important transaction codes:

a) Creation of Process orders can be done using the transaction code COR1 (Change is COR2, Display is COR3).

b) Similarly you can create a process order from the conversion of a planned order using the transaction code COR7 (individual conversion) or COR8 (collective planned order conversion).

c) To separately release a process order after its creation, you can use the transaction code COR5.

Upon the creation of the process order, the following activities are carried out automatically or manually in SAP PPPI as similar to a large extent to that in SAP PP:

a) Pull in the Master Recipe through the use of production versions. The master recipe would bring in the material list, the material quantity calculations associated with the material list.

b) Pull in the Relevant Bill of Material through the use of the production version. One can argue that the BOM is actually brought inside the production order when the master recipe is brought in and that argument is true to a large extent.

c) Batch Allocation is carried out automatically or manually in the process order.

d) The system executes all the formulas of the material quantity calculations using the batch allocations done in the component overview, thus changing the quantities of the header material and the components.

e) One can make the necessary changes to the operation overview of the process order, before the release of the process order, since the release of the process order would create the control recipe.

f) The creation of the process order creates a reservation number for the process order, thus reserving all the components for the process order execution.

g) The creation of the process order does not create a control recipe nor can you print any shop floor papers.

h) If the process order is created from a planned order, the basic dates and the quantities are copied. The production dates are calculated using the basic dates.

i) You can change/add/remove process instruction categories which are flown in as a part of the master recipe of the process order. There could be requirements of assigning values manually for some of the process instruction characteristics in some of the process instruction categories assigned to the control recipe destinations of the phase.

j) The release of the process order would create the control recipe for every given control recipe destination of the process order (if configured in production scheduling profile). If there are 2 control recipe destinations used in the process order then the system would create 2 control recipes for the process order.

k) The release can also carry out scheduling of the process order (if set in the production scheduling profile). The scheduling is carried out depending upon the parameters set in the scheduling parameters for a process order type. The capacity requirements are also generated for the resources if that is configured in the scheduling parameters.

l) You can also create a test control recipe in a process order, to check/validate certain things.

m) The scheduling, the capacity allocations procedures, the costing methodology, everything would remain the same as in SAP PP.

n) The process order creation process, the release process, the manual confirmation, the material staging, the goods issues, the goods receipts process, i.e., the overall execution process of a process order is exactly same as that of the production order in SAP PP and as spoken earlier in the previous paragraphs, but apart the creation of a control recipe and process management is an exclusive process of SAP PPPI.

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