Production Planning with SAP S/4HANA

3. Auflage 2025
ISBN: 978-1-4932-2673-3
Verlag: Rheinwerk Verlag GmbH

Buch, Englisch, 1084 Seiten, Format (B × H): 178 mm x 254 mm

Reihe: SAP PRESS: englisch

Configure and use SAP S/4HANA for discrete, process, and repetitive manufacturing! Walk through every aspect of production planning, from defining work centers and creating control recipes to releasing process orders and scrapping materials. Then dive into batch management, S&OP, DDMRP, pMRP, production engineering and operations, and more. This comprehensive guide is full of industry examples to help you maximize your production planning!

1) Discrete, process, and repetitive manufacturing
2) Batch management
3) Sales and operations planning (S&OP)
4) Demand management
5) Demand-driven replenishment (DDR)
6) Material requirements planning (MRP)
7) Predictive material and resource planning (pMRP)
8) Capacity requirements planning
9) Production planning and detailed scheduling (PP/DS)
10) Production engineering and operations
11) Kanban
12) Reporting and analysis

Autoren/Hrsg.

Akhtar, Jawad

Inhaltsverzeichnis

... Acknowledgments ... 27

... Preface ... 29

... Goals of This Book ... 29

... Target Audience ... 30

... Structure and Content ... 31

PART I ... Core Production Planning Concepts ... 35

1 ... Introduction to Production Planning with SAP S/4HANA ... 37

1.1 ... Production Planning and Control ... 37

1.2 ... Comparison Table of Production Types ... 50

1.3 ... Production Planning Features in SAP ERP and SAP S/4HANA: A Comparison ... 54

1.4 ... SAP Integrated Business Planning for Supply Chain ... 56

1.5 ... Summary ... 58

2 ... Organizational Structure in SAP S/4HANA ... 59

2.1 ... Breaking Down the Structure into Units ... 59

2.2 ... SAP Calendar ... 68

2.3 ... Summary ... 71

PART II ... Production Planning Configuration ... 73

3 ... Discrete Manufacturing Configuration ... 75

3.1 ... Material Master ... 76

3.2 ... Bill of Materials ... 77

3.3 ... Work Center ... 82

3.4 ... Routing ... 93

3.5 ... Production Order Configuration ... 94

3.6 ... Order Type–Dependent Plant Parameters ... 99

3.7 ... Production Scheduling Profile ... 103

3.8 ... Default Values for the Generation of Operations ... 105

3.9 ... Availability Check ... 106

3.10 ... Scheduling ... 111

3.11 ... Reduction Strategy ... 115

3.12 ... Confirmation ... 116

3.13 ... Reasons for Variances ... 124

3.14 ... Trigger Points ... 125

3.15 ... Defining Print Control ... 125

3.16 ... Background Jobs ... 126

3.17 ... Summary ... 127

4 ... Process Manufacturing Configuration ... 129

4.1 ... Master Data in Process Industries ... 130

4.2 ... Order Type–Dependent Parameters ... 133

4.3 ... Production Scheduling Profile ... 136

4.4 ... Process Management ... 137

4.5 ... Process Messages ... 141

4.6 ... Process Instruction Categories ... 147

4.7 ... Control Recipe/Process Instruction Sheets ... 162

4.8 ... Background Jobs ... 166

4.9 ... Process Manufacturing Cockpit ... 168

4.10 ... Summary ... 170

5 ... Repetitive Manufacturing Configuration ... 171

5.1 ... Repetitive Manufacturing Profile ... 172

5.2 ... Scheduling Planned Orders ... 183

5.3 ... Display ... 184

5.4 ... Material Staging ... 186

5.5 ... Global Settings for Confirmation and the Logistics Information System ... 187

5.6 ... Operational Methods Sheet ... 188

5.7 ... Summary ... 189

PART III ... Production Planning Workflows ... 191

6 ... Production Planning for Discrete Manufacturing ... 193

6.1 ... Process Overview ... 194

6.2 ... Master Data ... 195

6.3 ... Production Order Management ... 230

6.4 ... Releasing Production Orders ... 248

6.5 ... Printing ... 251

6.6 ... Material Withdrawal ... 253

6.7 ... Confirmation ... 260

6.8 ... Goods Receipt ... 266

6.9 ... Postprocessing ... 268

6.10 ... Settlement and Completion ... 271

6.11 ... Additional Functions and Information Systems ... 272

6.12 ... Summary ... 276

7 ... Production Planning for Process Manufacturing ... 277

7.1 ... Process Manufacturing Overview ... 278

7.2 ... Master Data in Process Manufacturing ... 279

7.3 ... Characteristics ... 288

7.4 ... Process Management ... 292

7.5 ... Process Order Execution ... 306

7.6 ... Process Management in Action ... 307

7.7 ... Execution Steps ... 317

7.8 ... Process Message Evaluation ... 329

7.9 ... Process Manufacturing Cockpit ... 330

7.10 ... Resources Network ... 331

7.11 ... Summary ... 335

8 ... Production Planning for Repetitive Manufacturing ... 337

8.1 ... Overview ... 338

8.2 ... Master Data ... 341

8.3 ... Material Requirements Planning in Repetitive Manufacturing ... 358

8.4 ... Planning Table ... 361

8.5 ... Material Staging ... 371

8.6 ... Production List ... 374

8.7 ... Confirmation ... 375

8.8 ... Reversals and Scrap ... 384

8.9 ... Costing Activities (Cost Object Controlling) ... 389

8.10 ... Heijunka ... 390

8.11 ... Reporting ... 392

8.12 ... Summary ... 393

PART IV ... Production Planning Tools ... 395

9 ... Kanban ... 397

9.1 ... Kanban Overview ... 398

9.2 ... Push-Pull Principle ... 400

9.3 ... Kanban Replenishment Strategies ... 402

9.4 ... Configuring Kanban ... 404

9.5 ... Setting Up Kanban Master Data ... 417

9.6 ... Replenishment with Kanban ... 421

9.7 ... Evaluating and Reporting Kanban ... 449

9.8 ... Summary ... 455

10 ... Batch Management ... 457

10.1 ... Batch Management Overview ... 457

10.2 ... Batch Level and Batch Status Management ... 459

10.3 ... Master Data in Batch Management ... 463

10.4 ... Business Processes of Batch Management ... 468

10.5 ... Batch Determination ... 474

10.6 ... Recurring Inspection and Expiration Dates ... 488

10.7 ... Active Ingredient Management ... 495

10.8 ... Batch Derivation ... 518

10.9 ... Batch Traceability of Work in Process Batches ... 529

10.10 ... Batch Information Cockpit ... 540

10.11 ... Electronic Batch Record ... 542

10.12 ... Summary ... 544

11 ... Sales and Operations Planning ... 545

11.1 ... Standard Sales and Operations Planning ... 546

11.2 ... Flexible Planning ... 564

11.3 ... Version Management ... 585

11.4 ... Forecasting ... 587

11.5 ... Rough-Cut Planning Profile ... 600

11.6 ... Events ... 605

11.7 ... Mass Processing in Sales and Operations Planning ... 610

11.8 ... Standard Analysis in Flexible Planning ... 612

11.9 ... Summary ... 615

12 ... Demand Management ... 617

12.1 ... Elements of Demand Management ... 618

12.2 ... Strategies for Make-to-Stock Production ... 624

12.3 ... Strategies for Make-to-Order Production ... 635

12.4 ... Strategies for Assemble-to-Order ... 641

12.5 ... Strategies for Planning Components ... 646

12.6 ... Production with Variant Configuration ... 649

12.7 ... Creating a Custom Requirement Class ... 652

12.8 ... Business Processes in Demand Management ... 656

12.9 ... Summary ... 669

13 ... Material Requirements Planning ... 671

13.1 ... Process Overview ... 672

13.2 ... Deterministic Replenishment Procedures ... 679

13.3 ... Stochastic Replenishment Procedures ... 691

13.4 ... Configuring Material Requirements Planning Types ... 696

13.5 ... Lot Sizing Procedures ... 699

13.6 ... Rounding ... 707

13.7 ... Scrap ... 709

13.8 ... Safety Stock ... 712

13.9 ... Scheduling ... 720

13.10 ... Procurement Proposals ... 725

13.11 ... Configuration Settings for Material Requirements Planning ... 732

13.12 ... MRP Live ... 735

13.13 ... Stock/Requirements List ... 740

13.14 ... Planning Calendar ... 756

13.15 ... Planning Areas ... 758

13.16 ... Classic Material Requirements Planning ... 764

13.17 ... Types of Planning Runs ... 766

13.18 ... Summary ... 767

14 ... Demand-Driven Replenishment ... 769

14.1 ... Limitations of Current Materials Planning and Replenishment Tools ... 770

14.2 ... Material and Information Flows ... 772

14.3 ... Demand-Driven Material Requirements Planning Basics and Components ... 774

14.4 ... Demand-Driven Material Requirements Planning Setup ... 785

14.5 ... Running Demand-Driven Replenishment ... 796

14.6 ... Summary ... 835

15 ... Predictive Material and Resource Planning ... 837

15.1 ... Basics ... 838

15.2 ... Setup ... 839

15.3 ... Managing pMRP ... 844

15.4 ... Releasing Results to Operative Material Requirements Planning ... 852

15.5 ... Using Flexible Constraints ... 855

15.6 ... Summary ... 856

16 ... Capacity Requirements Planning ... 857

16.1 ... Process Overview ... 858

16.2 ... Capacity Requirements and Capacity Evaluation ... 860

16.3 ... Finite Scheduling ... 875

16.4 ... Dispatching ... 876

16.5 ... Capacity Planning Table ... 890

16.6 ... Summary ... 896

17 ... Production Planning and Detailed Scheduling ... 897

17.1 ... Configuration ... 898

17.2 ... Master Data in PP/DS ... 905

17.3 ... Business Processes ... 920

17.4 ... Heuristics ... 927

17.5 ... Production Planning Run ... 929

17.6 ... Reporting and Monitoring Apps ... 943

17.7 ... Alert Monitor ... 949

17.8 ... Plan Monitor ... 951

17.9 ... Summary ... 955

18 ... Production Engineering and Operations ... 957

18.1 ... Key Terminology ... 959

18.2 ... Configuration Settings and Production Engineering and Operations Setup ... 960

18.3 ... Production Engineering Master Data Setup ... 970

18.4 ... Planning in Production Engineering ... 984

18.5 ... Production Operations ... 989

18.6 ... Reporting ... 1004

18.7 ... Summary ... 1008

PART V ... Monitoring and Evaluating Production Planning ... 1009

19 ... Production Planning Reporting ... 1011

19.1 ... The Basics of Reporting ... 1011

19.2 ... Report Parameters ... 1012

19.3 ... Order Information System Reports ... 1023

19.4 ... Missing Parts Information System ... 1025

19.5 ... Summary ... 1026

20 ... Standard Planning Analysis ... 1027

20.1 ... Discrete Manufacturing/Production Order ... 1027

20.2 ... Process Manufacturing/Process Order ... 1033

20.3 ... Repetitive Manufacturing ... 1033

20.4 ... Additional Analysis Functions ... 1034

20.5 ... Summary ... 1037

21 ... SAP Fiori Apps for Production Planning ... 1039

21.1 ... SAP Fiori Launchpad and SAP Fiori Apps Reference Library ... 1039

21.2 ... SAP Fiori Applications ... 1040

21.3 ... Summary ... 1064

... The Author ... 1065

... Index ... 1067

Über Autor(innen)

Akhtar, Jawad
Jawad Akhtar is an SAP logistics and supply chain management expert with a focus on business sales and delivery. He earned his chemical engineering degree from Missouri University of Science and Technology in the United States. He has 20 years of professional experience, 14 of which have been spent working with SAP systems. He has experience working on several large-scale, end-to-end SAP project implementation lifecycles, including rollouts. He works with SAP clients to help them identify root causes of business issues and address those with the appropriate SAP products and change management strategies. He now focuses on next-generation SAP products such as SAP S/4HANA, SAP IBP, SAP Ariba, and SAP Hybris.

Akhtar is also a technical advisor to SAPexperts, an ASUG speaker, and a contributor to SearchSAP, where his "Ask the Expert" column shares real-life lessons and best practices gleaned from SAP implementations, ways to avoid common project pitfalls, and features of various SAP products that solve key business issues.