Course Content

I. Overview of ERP

About SAP

SAP Hierarchy Structure

II. Master Data

 Material Master

 Bills of Material

 Work Center

 Routing

 Production Resource Tools

 Engineering Change Master

III. Product Group Planning

 Aggregation/disaggregation

 Events

 Plant Distribution

IV.Material Requirement Planning

 MRP Parameters

 Conversion To planned Orders

 Evaluation

 Single /Multiple Item /Multiple Level Planning

V. Capacity Planning

 Availability Capacity

 Evaluation

 Overloading / Under Utilization

 Levelling of Capacity

VI. Production Control

 Types of Order C01

 Confirmation

 WIP, Variances, Settlement MI01/04/20

VI. KANBAAN

 Control Cycle PK01

 Trigger Mechanism / KANBAAN Board PK13N/12/10

 Back Flush PK41

VII. Production Cost Planning

 Cost structure KKF6N

 Costing Run & How to Handle Errors CK40N

VIII. PLAN ORDER Creation

 SOP-Std.

 SOP-Flexible

 Planned ind. req.(PIR)

 W/o MRP

IX. Variant Configuration in PP

Variant Configuration in BOM

 Characteristics

 Class

 Classification

 Classification settings in material master

 Maintain Dependency

 Configurable Profile for Material

X. Availability Check

 Availability Check with ATP Logic or Against Planning

XI. Discrete Manufacturing

 Planned order structure

 Production order types

 Material staging and withdraw

 Production confirmation

 Goods movements

 Goods Receipt WREF to Production Order

 Goods Issue WREF to Production Order

 Creation of GI WREF to Reservation

 Restricting Goods Receipt Unless Production Order is confirmed

 Order settlement

XII. Reporting & Tools

 Production planning reporting

 Material requirement planning reporting

 Maintenance of master data using mass change function

XIII. INTEGRATION OF PP WITH OTHER MODULES

 MM

 SD

 QM

 WM

 FI

Additional Topics

 SAP S4 HANA Certification Questions

 Real Time Support Tickets

 Resume Preparation

 Interview Questions

 SAP PP Configuration Documents

 SAP PP Business Blue Prints & Functional Specifications

 Project Guidance

 JOB Guidance

 Project Details

Trainer Profile

Interview Questions & Answer

1) What is SAP PP?

SAP PP (Production Planning) is one of the largest functional module in SAP. It generally encompasses the integration and streamlining of the varied needs of a manufacturing enterprise and takes care of the proper planning of its allied processes. Globally, the main function of a production department is to produce reliable goods and services for end user consumption -  in the cost effective way. therefore, a smartly conceived and well-organized production department is of utmost importance for higher productivity and profit-making figures alike.

Production planning functionalities generally include:

• Planning of schedules
• Dispatching inspection
• Co-ordination and control of raw materials, employees and tools for achieving high quality products and meeting customer demands.

2) What are the components of SAP PP?

SAP Production Planning (PP) is composed of the following components

• DM (Data Management)

• LTP (Long term planning)

• MRP(Material Requirement Planning)

• MPS (Master Production Schedule)

• SOP (Sales Operation Planning)

• Bills of Material (BOM)

• Shop Floor Control

• CRP (Capacity Requirement Planning)

• Automatic material requisitions on the basis of MRP

• Capacity planning

• Routings

• Information systems and so forth.

These SAP PP components make it easy to streamline the smaller details of the manufacturing process and can appropriately record and track planned costs, material flows and actual costs to perfection. This module is totally integrated with other SAP modules like SAP MM SAP PP SAP FI CO SAP PM AMD SAP LE:

SAP PP effectively handles all business processes relevant to the production of a manufacturing unit. Here, the R/3 system modular data is appropriately classified as transaction data and master data; where the latter is defined in the form of individual module objects. These PP Master Data objects must be used prior to the use of transactions.

3) Can we create Production order without BOM and routing?

Yes, we can create a production order without BOM and routing. For this change the config in OPL8 (order type dependent parameters) as routing optional. But it may ask for a sales order when we try to create order using C001.

4) What Is MRP List and What Is the Use Of It?

The system creates MRP lists during the planning run according to how you set the creation indicator. These lists contain the planning result for the material. The MRP list always displays the stock/requirements situation at the time of the last planning run. it also provides a work basis for the MRP controller. Changes that are made after the planning date are not taken into consideration, so the list is static.

MRP lists are stored in the system until they are either deleted manually or replaced by new lists from a subsequent planning run.

5) What Is Opening Period?

The opening period shows the number of workdays that are subtracted from the order start date in order to determine the order creation date. This time is used by the MRP controller as a float for converting planned orders into purchase requisitions or into production orders.

6) What is the difference between Material and sales order BOM?

Material BOM

When a Bill of Material is created for a material is known as a material BOM in the SAP. Material BOMs are mainly used to represent the structure of products manufactured within your company.

Sales order BOM

Sales Order BOM is used when you specially tailor or customise the make-to-order production of products as per requirements of the customers. To meet the customer requirements, you make sales order specific modifications to various assemblies.

7) What Is Group Bom?

Group BOM is Alphanumeric character string used to uniquely identify a BOM.

Use:If you assign a "meaningful" number to a BOM group, this gives you an additional way of accessing the BOM.

The system stores the following under a BOM group:

• All the alternatives in a multiple BOM
• All the BOMs entered for a variant BOM

8) What are the characteristics of BOM?

• You can create Bill of Material as single level or multiple level.
• BOM type depends on the size, validity dates and production method.
• You can create up to 99 Bills of Material as per material type.
• You can use material Bill of material for the material available in PP module and equipment Bill of Material are used in Plant Maintenance module.
• you can create super BOM for different variants of a product.

9) What Are Gaps? Give some Examples?

The Gaps are some issue in blue print that SAP cannot capture or providing the client business process.

10) What is routing process under PP?

Routing is the list of activities to be performed for production process. Routing defines sequence of activities performed at work center. Routing plays an important role in calculating production cost, machine time and labour time.

11) What is the use of routing in PP?

To create routing it is mandate that you first define work center.

Multiple material can follow single routing group.

Routing is used for scheduling and costing of operation for raw and finished products.

Routing is used for calculation operation cost for finished product.

12) What is capacity planning and capacity leveling?

Capacity Planning is done to balance the load at work center and you can calculate production capacity based on requirement of product as per available capacity.

Capacity leveling is performed for performing detailed production planning purpose. This is done through planning table which is used to carry detailed planning of capacity requirements over time in future.

13) How to perform capacity leveling under PP?

You can perform Capacity Leveling using Planning table. The orders are processed as defined in work center to meet the Production process.

To perform Capacity leveling, use T-Code: CM21

14) Differentiate between MD04 and MD05.

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