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Master Data Explosion in SAP Production Order or Process order

 
 

SAP Routing/Recipes Explosion in the Production Order / Process Order

 
SAP Routing/Recipes Explosion in the Production order / Process Order

 

 

A Routing is a task list which acts as a place holder for the sequence of operations required for manufacturing a product. It is a created as a master data in SAP. Upon selection of a Routing/Recipe the operations, work centers and the activities are transferred to the order.

 

 
For Manual Routing/Recipe Selection

 

Configuration: You have to choose in the “order type dependent parameter settings” for an order type whether you want to select the Routing/Recipe manually or automatically. You can choose manual selection if you choose to.

 

0

No routings or reference operation sets to be used

1

Always reference operation set (no routings selected)

2

Routing/ref. op. set mandatory (automatic selection)

3

Routing/ref. op. set optional (automatic selection)

4

Routing/ref. op. set optional (manual selection)

5

Routing/ref. op. set mandatory (manual selection)

6

Routing mandatory (automatic selection)

7

Routing mandatory (manual selection)

8

Routing optional (manual selection)

9

Routing optional (automatic selection)

 

 

If you choose any of thee manual selection option in the order type dependent parameter settings, SAP will offer a Task list pop-up selection in the “order creation” allowing you choose from the list of Routings/Recipes group counters created for the material as a part of master data.

 

What Criteria are checked when it is pulled in the Order: When the system offers a list of task lists to choose from, it pulls in Routings/recipes for the production order header material which is valid from the order start date and whose lot sizes matches with the production order quantity.

 
 
For Automatic Routing/Recipe Selection

 

 

In the Routings or the Recipes configuration, we have to create a “Selection ID” and assign the same in the “Order type Dependent Parameter settings”, thus allowing the SAP to choose a valid Routing/Recipe during order creation.

 

Normally for SAP PP, you can choose the standard “01” Selection ID and for SAP PPPI you can choose the “02” Selection ID or create your own.

 

Actual Selection: When the system chooses a Routing/Recipe, it pulls in Routings/recipes for the production order header material which is valid from the order start to order finish date and whose lot sizes matches with the production order quantity.

 

Jeopardy: When automatically selecting a valid Routing/Recipe, if the system comes across more than one selection, it again throws the ball in your court and asks you to select manually from that list.  

 

Unfaithful: During automatic Routing/Recipe selection, if the system results in not finding a valid Routing/Recipe it would abort the creation of the production order unless and until the below case is true.

 
 
Automatic Routing/Recipe Selection Along with BOM selection through Production Versions
 
 
When you choose automatic Routings/Recipe selection and at the same time if you have chosen BOM selection through Production versions, in which case if there is a Routing/Recipe also assigned to the Production version the system would choose that Routing/Recipe instead of using the automatic Routing selection (through selection ID set in configuration).
 
 

SAP BOM Explosion in the Production order / Process Order

 
SAP BOM Explosion in the Production order / Process Order

 

 

A Bill of Material contains the list of raw materials that are required for production of a base quantity of the header material.

 

Configuration: When an order is created, you can choose whether you want the BOM to be pulled in the order or not, by entering a desired “BOM Usage” in the “Order type dependent parameter settings”. Including an order type, you are actually helping the system to pull a Material BOM of a desired usage.

 

Another place where setting is done: And if you choose to automatically explode the BOM in the order through the above configuration, the actual pulling of the Material BOM in the order is performed by the value selected in the “Select BOM explosion Method” field in the MRP 4 view.

 

 

Selection by order quant.

1

Selection by explosion date

2

Selection by production version

3

Selection only by production version

 

 

 

When is the BOM pulled in / BOM Explosion Date: SAP pulls in the BOM, a split second after the Routing is attached and the order is scheduled so that it gets the Order start date or Order Finish Date and the BOM explosion number and uses it as BOM explosion date. You can carry out these settings in transaction code OPPQ. The standard setting is “Order start date”.

 

BOM Explosion Methods: If you choose to explode the BOM, then one of the above 4 option has to be selected in the material master:
 

 

Selection by order quant.

1

Selection by explosion date

2

Selection by production version

3

Selection only by production version

 

 

 

a)      If you  choose to explode by order quantity then a BOM is exploded for the material based on the lot size criteria, provided the BOM is valid for the order start and order finish date.

 

b)       If you choose to explode by explosion date then only the validity dates of the BOM come in to picture, i.e., the BOM should be valid through the order start and finish date.  

 

c)       If you choose to explode the BOM through production version then explosion is purely based upon the lot size, validity dates and the BOM maintained in the production version, and if a valid production version does not fit then the system gives you an option to choose the BOM through manual selection methods.

 

d)       If you choose to explode the BOM through “only production version” method then explosion is mandatorily based upon the BOM found in the version for lot size and date validity and if a valid production version is not found then order creation is aborted.

 

Note: Unless and until you use the selection method as the Production Version selection method, the system will always choose the BOM alternatives

 

 
 
Why does a BOM does not get exploded in the Order:
 
 
A Material BOM fails to get exploded in the production order, because:
 
a) The BOM is not active and must have been set to inactive status in the BOM header screen
 
b) The BOM is not valid for the order lot size, i.e., the BOM lot size range is does not fail in the order quantity.
 
c) The BOM is not valid for the order basic dates, i.e., the BOM validity dates is different than the order basic dates; the BOM is not valid in the date range for which the order is created.
 
d) If you pulling in the BOM in the order, through the use of Production Versions, then the lot sizes and the version validity dates should fall in the order quantity and the order basic dates, similar to what is mentioned in the point number b and c.
 
e) If the BOM that is being pulled in, is not relevant for production.
 
f) If the Material Master X-Plant Status or the Material Master Plant Status is set to disallow production.
 
g) If the BOM is not configured to be pulled in the order as per the order type specific configurations.