The Warehouse Management (WM) application component is interfaced to the Production Planning Shop Floor Control (PP-SFC) application component to assist in providing materials to supply areas in production. The significant advantage for customers using this WM-PP interface is that it provides pinpoint accuracy in timing the supply of materials to production storage bins in production supply areas.
The basic concept is for workers in production to be able to order needed materials themselves, which, in turn initiates the creation of transfer requirements in WM. Warehouse Management component, then, is responsible for supplying needed materials to the storage bins in production.
It does so by creating a transfer order for each respective transfer requirement. This is part of the standard WM procedure.
The subsequent goods issue posting reduces the stock quantity of materials that have been removed from “production” storage bins and no additional activities are required in WM.
For each material and production supply area in a plant, you must clearly define the storage bins to which the necessary materials will be supplied and the type of material staging that will be implemented. This is known as a control cycle.
The system supports the following types of material staging:
You can request material staging in advance so that the required materials are supplied using WM (transfer requirement / transfer order) at the correct time. Also, no further activity is required for the consumption posting.
When you use the WM component the assignment of plant and storage location to a warehouse number and from plant and warehouse number to storage location must be clearly established. Within a plant, you can manage one or several storage locations per warehouse number.
Using WM for material staging requires care and strict discipline in system handling. Materials may only be used for production by removing them from production storage bins that were defined for that purpose. If the needed stock is located in another location, it must be moved from that location to the production storage bin, because it is from that bin that the consumption posting will take place. If this practice is not consistently adhered to, the efficient use of the system will be significantly hindered by the increase in unnecessary stock differences.
The following changes in the production order affect the WM-PP interface:
Whatever the case, the bin coordinates listed in the production order for the consumption posting are updated. Also, any existing superfluous transfer requirements for pick parts are canceled and missing quantities are requested, if necessary (only in the case of automatic requests). If a transfer order has already been created for a material supply request, it cannot be canceled. However, the additional/new material requirement is issued.
Confirmation of Batches in Fixed Storage Bins
The return confirmation of batches issued in WM for a production order can only take place for pick parts. When dynamic production storage bins are used, this confirmation takes place automatically since in this case the system carries out the assignment of batches and production orders. If pick parts are supplied to a fixed production storage bin that was defined in the control cycle during WM staging, there is no definitive assignment between the production order and the batches that are found because such bins are used for several production orders. In this case, if a notification is to take place, it must be explicitly configured as such in Customizing. The confirmation of batches is not supported for quantity reduction.
Quantity Reduction in the Case of Surplus Quantities
When you create transfer orders for transfer requirements that include the picking requirement for a production order, the quantity can reduced if you determine that there is a surplus quantity (available stock) in the storage bin.
The reserved quantity is the quantity that was requested in orders for a particular production storage bin, minus the quantities already removed from this bin. The system only calculates positive quantities. The reserved quantity is deducted from the total of the available stock and stock to be placed into the bin as well as the open transfer requirement quantities. The positive difference is the available stock that is deducted from the transfer order quantity with respect to the transfer requirement quantity.
This means that the individual tasks are clearly defined. In the production department, the WM material staging process is initiated for all released orders and the warehouse is responsible for processing all open transfer orders. During TO creation, only those quantities are transferred that have not been moved to production for other reasons.
A material that is made available in the quantity required in the production order.
This object can be provided in a physical storage bin or in the dynamic storage bin entitled “Production Order”. For this type of material staging, you can create transfer requirements in two different ways:
You can set up the system for this to take place automatically when the production order is released.
You can create transfer requirements for each component manually once the production order has been released.
Transfer requirements that are created in this manner are always based on the quantity required in the production order and the production deadlines.
In both PP and WM, you can use a separate transaction to create transfer requirements for parts that are needed in various quantities and at different times for a specific production order. The requirement number in the transfer requirement is the same as the order number. If the order number is longer than 10 digits, it is shortened accordingly.
Material that is stored in crates or other standard containers and is requested -- independent of existing production orders -- as the quantity defined in the control cycle. With this material staging method, you use a separate transaction to order another full crate.
In the standard system, this object is always ordered manually. When a worker on the shop floor notices that a container or particular production storage bin is becoming empty, the worker uses the Warehouse Management (WM) or Production Planning Shop Floor Control (PP-SFC) component to replenish the bin using this transaction. You define the quantities required in the control cycle.
The request for the provision of these parts can be processed in the background as soon as you have entered the material, the production supply area, and the plant. The transfer requirement uses the production supply area as the requirement number; dynamic bin coordinates are not supported.
Release Order Part
Material that is requested, independent of the order. The requesting individual in the production department determines the amount of materials to be supplied.
The amount of this object to be supplied is supported by the following information:
In addition, you can display information on the standard pallet quantity as well as the stock in quality inspection. On the basis of this information, you determine the required quantity manually.
Depending on your selection, the data includes:
If you have large volumes of data, it is appropriate for performance reasons to limit the selection. In addition to the required entry of the plant and the production supply area, you limit your selection further by specifying the material, the requirements date, and/or the order number. The transfer requirement lists the production supply area as the requirement number; dynamic coordinates are not supported.
Release order parts are scheduled manually based on the requirements of production orders, the stock levels at supply areas in the production department and available quantities in replenishment storage types.
Production workers can display an overview of all purchase orders that have been released and estimate their requirements for a particular time period. To determine the quantity to request, they can display figures on the stock levels in the production bins and in the WM storage types that are used to supply the replenishment quantities.
Setting up the Interface between PP and WM
To set up the interface between Warehouse Management and the Production Planning application components, you must carry out the following steps:
To assign the movement type to replenish production storage bins, see Interfaces → Define production data in the Warehouse Management IMG documentation.
You must define the replenishment movement type for this storage type. Do not active SU-management and do not define a putaway or pick strategy.
Production Supply Areas
Production supply areas (PSAs) are used for material replenishment and are situated directly on the shop floor in the production department. The supply area groups work centers near production storage bins based on the material staging methods. You need to enter the PSA in the work center master data.
To create production supply areas in Customizing for Warehouse Management in your system, choose Logistics Execution → Warehouse Management → Interfaces → Define Production.
Creating a Control Cycle
The control cycle record is made up of the plant, production supply area and material and determines for the WM-PP interface the production storage bin and the type of material staging that is used. The production storage bin is defined by the whole key: warehouse number, storage type and bin.
You create control cycles by choosing Logistics → Logistics Execution → Master Data → Warehouse →Production Supply → Control Cycle Production Supply → Create from the SAP menu.
You can also define a control cycle without specifying the material. This general entry is valid for all materials in the supply area for which no control cycle has been defined.
Displaying Control Cycles
To display a list of existing control cycles, choose Logistics → Logistics Execution → Information System → Warehouse → Production Supply → List of Ctrl Cycles from the SAP menu.
Control cycles are managed using number ranges that are established in PP. Therefore, you should ensure that number ranges have been created for control cycles before using this interface. To create number ranges for control cycles, see Kanban → Define number range for control cycle in Customizing for Production.
Production Storage Bins
Production storage bins that are used for material staging are determined by the system based on the control cycle. Production workers must pick parts for production only from production storage bins. Otherwise, discrepancies in stock quantities in WM will result. The storage bin can be defined as a
To create the necessary physical production storage bins, choose Master data → Storage bin→ Create from the WM menu bar..
The Material Staging Process
There are several tasks involved in the implementation of the material staging process. So that you can understand how this process takes place in the system, we describe how you can carry out the following tasks in the SAP system manually. To implement the material staging process using WM, perform the following tasks in the order listed below:
Creating a Production Order
Before you can carry out any actions in WM to transfer materials to a production storage bin using the WM–PP interface, you must first create a production order. To create a production order, see the PP component documentation on Production Orders.
Displaying a Production Order
To display a production order, choose Logistics → Production → Production Control → Order
The component overview lists all components needed to assemble the final product. When you created the production order, several tasks were carried out. The following features are relevant for the WM-PP interface:
Releasing a Production Order
When you release a production order, the system determines the type of material staging and to which production bins the components must be moved. If you have activated automatic staging, the system creates transfer requirements automatically in WM. To release the production order
Without automatic staging, you may request the pick parts normally by choosing Order → Functions → WM mat. provision → Proceed or by choosing Goto → WM Pick list in the place of Step 3.
Once you have released the production order, you should create and confirm transfer orders from the transfer requirements that you created to supply materials to production. This actually moves the materials to the production storage bins in the supply areas that will then be used to assemble the product requested in the production order.
Automatic Staging for WM
If you have activated automatic staging, the system will request all pick parts in a production order automatically when it is released. The decision whether automatic staging will take place is made at the production level, not for each component.
Customer Exit for Automated TR Generation
When you use this exit, you can automate the generation of transfer requirements during WM staging for production orders. More detailed information is available in the report documentation (MWMPP001).
For information on how to activate automatic staging for WM, see Interfaces _ Define production data in the Warehouse Management IMG documentation.
For automatic WM staging, you need to ensure that each transfer requirement created by the system contains all components that are relevant for WM staging. You can make a setting in Customizing that prevents the generation of incomplete transfer orders. With this setting, the system will not create transfer requirements unless it contains all relevant components.
Additionally, a message is entered in the log that references this error. You define this function in the warehouse number control section in Customizing. This completeness check does not refer to the entire production order, instead, it refers only to the process concerned.
When the system creates transfer requirements, the required quantity of the components is copied over as the requested quantity as a default entry. Even when the material is not available or is only partially available, the total required quantity of the components is carried over into the transfer requirement quantity. This could result in the creation of transfer orders for production orders for which there are insufficient materials available. On the other hand, materials may only be partially supplied or not supplied at all for production orders for which the available quantity was actually confirmed.
You can define in Customizing that the confirmed quantity of a component is to be carried over as the requested quantity. This type of staging has only been implemented for pick parts since these parts are staged based on a production order.
Quantity Reduction in the Case of Surplus Quantities
When you create transfer orders for transfer requirements that include the picking requirements for a production order, the quantity can reduced if you determine that there is a surplus quantity (available stock) in the (fixed) storage bin in production.
The determination of the available quantity in the production storage bins affects system performance significantly and takes place even if it is not necessary (for example, when the requested quantity is staged in the exact amount without overdeliveries. In Customizing, you can switch off quantity reduction for each storage type separately if this is desirable.
Calculating the Available Quantity
The reserved quantity is the quantity that was requested in orders for a particular production storage bin, minus the quantities already removed from this bin. The system only calculates positive quantities. Transfer requirements that are created manually are not taken into consideration. All transfer requirements that refer to a production order are taken into consideration. In these transfer requirements, items that do not refer to open reservations (for example, transfer requirements that refer to deleted reservations or to a production order that has been technically completed) are not taken into consideration.
The reserved quantity is deducted from the total of the available stock and stock to be placed into the bin as well as the open transfer requirement quantities. The positive difference is the available stock that is deducted from the transfer order quantity with respect to the transfer requirement quantity.
The individual tasks are clearly defined. In production, the WM material staging process is initiated for all released orders and the warehouse is responsible for processing all open transfer orders. During TO creation, only those quantities are transferred that have not been moved to production for other reasons.
Optimized Database Access to Transfer Requirements
As a rule, the system accesses transfer requirements during quantity reduction via the destination storage type index. This can lead to performance problems for some combinations. As alternatives, the system can also access the transfer requirements via the material number or via a DATABASE-TABLE-JOIN. You can select this access in Customizing in the storage type controls under Interface → Define production.
Displaying TRs for Material Staging
When you release a production order, the system may generate more than one transfer requirement (TR). This happens, for example, when the production order requires picking from several production bins in the production department.
To display transfer requirements
The TR number in transfer requirements created for a production order consists of two parts:
For pick parts, the system uses P plus the production order number as the requirement number. For crate parts and release order parts the requirement number is P plus the supply area designator.
Additional information in the TR header indicates that this is a special kind of transfer requirement. For example, the description indicates that the transfer requirement was generated via the WM-PP interface.
Creating TRs for Material Staging Manually
To initiate the supply of materials to storage bins at production supply areas, you must create transfer requirements that are based on production orders or on material requirements in the production bins.
To create material staging transfer requirements for a production order manually, choose Logistics → Logistics Execution → Outbound Process → Goods Issue for Other Transactions→ Prepare Production Supply → For Order from the SAP menu.
This material staging method using a separate transaction is more flexible than creating transfer requirements from the production order because it allows you to process smaller quantities and percentages of a production order based on individual workstation requirements. To use this method, you need to deactivate automatic staging.
To create transfer requirements for crate parts, choose Logistics → Logistics Execution → Outbound Process → Goods Issue for Other Transactions→ Prepare Production Supply → For Crate Part from the SAP menu.
Release Order Parts
To create transfer requirements for release order parts, choose Logistics → Logistics Execution → Outbound Process → Goods Issue for Other Transactions→ Prepare Production Supply → For Release Order Part from the SAP menu.
When creating transfer requirements for release order parts, you can display all the production orders that use the material requested in the selected supply area. How you process subsequent screens for all three methods of material staging is generally self explanatory and is described in the online documentation for individual data fields.
Units of Measure
t is possible for you to select a specific unit of measure for the supply of pick parts and release order parts to production. You specify the unit of measure while carrying out material staging.
When you create transfer requirements for production supply in WM (or in PP), you can select the unit of measure to be used for displaying the material staging list. Choose Edit → Unit of Measure on the material staging overview screen. The system displays a dialog box in which you can enter the desired unit of measure. When you select one of the options, the system displays the quantity fields in the material staging list with the unit of measure of your choice. The transfer requirements created for this material staging list will then be generated using the selected unit of measure.
The unit of measure you choose is stored in the Parameter ID “LMB”, so that the next time you carry out the material staging task, the unit of measure you selected previously is automatically suggested as a default.
Setting a Default Unit of Measure for Material Staging
To set a default unit of measure for material staging, choose Tools → Administration → User Maintenance → Users. In Parameters, enter one of the following parameters for parameter ID “LMB”:
When you define the control cycle for crate parts, you can define any unit of measure for container quantities. The system then uses the unit of measure defined in the control cycle record when calling up material staging for crate parts.
Processing TRs for Material Staging
Once the transfer requirements for production supply have been created, you process them in the same manner as all other transfer requirements in WM. You create transfer orders based on transfer requirements and confirm them. The transfer orders created from transfer requirements
The system does not create incomplete transfer orders for transfer requirements. If one item (the total quantity of material in a transfer requirement item) cannot be converted, the system will not create a transfer order for the rest of the items.
Creating Transfer Orders for Material Staging Automatically
When using the WM-PP interface, you can activate immediate transfer order creation from within the material staging process. Immediate transfer order creation means that the transfer requirement created for material staging is automatically converted into a transfer order. Immediately after the transfer requirement for material staging has been created, the system creates a transfer order in the background for this transfer requirement. If an error occurs, a corresponding error message can be sent to a particular user via the general mail control function.
You can request immediate transfer order creation manually for all material staging functions. For this purpose, users require the WM authorization "Special functions in Warehouse Management" with the setting "1".
If material staging of pick parts is requested automatically (rather than manually) when production orders are released, you need to define the Production control profile to activate immediate transfer order creation. Maintain the mail control function in the replenishment storage type or in the production storage type using the Define storage type task.
In the Warehouse Management movement type, you can set a switch (Automatic TO) that causes the system to create transfer orders automatically. To make changes to the movement types in WM, choose Logistics Execution → Warehouse Management → Activities → Transfers → Define Movement Types in Customizing for Warehouse Management.
Posting a Goods Issue for Material Usage
The final step in the material staging process is to post a goods issue for consumption. When a production order is completed, the materials have been removed from the production storage bins in the warehouse and the final product has been fully assembled, it is still necessary to balance the stock quantities in IM and WM.
You post the use of materials to the database either by “backflushing” with the completion confirmation or directly in Inventory Management. This posting is necessary to reduce the stock quantities in the production storage bins of the WM and IM components.
To post the goods issue for material usage
To process the goods issue in the PP component, choose Logistics _ Productionprocess _ Process order _ Environment _ Material movement _ Withdraw material from the SAP menu.
The system displays a dialog box in which you must enter the production order number as a minimum. When you post the goods issue, it is important that you enter the production order number. The system will only reduce the quantities in the production storage bins if you enter the production order number on this screen. Otherwise, it will post the material to the general interface and create transfer requirements.
Since the transfer requirement for the production order was created far in advance of this goods issue posting, the materials are delivered in a timely manner to the production storage bins. You post the actual goods issue in IM (or in PP) afterthe product has been assembled in production.
Since the production storage bin was noted in the production order when it was released, the material usage posting reduces the quantity in the production bins and no further action is required in WM.
At this point, the finished product is located in production. Follow-on functions exist in PP for further processing. If you want to store the finished product in the warehouse, settings can be made in the PP IMG to trigger a goods receipt in IM. In turn, the goods receipt in IM triggers the creation of a transfer requirement or transfer order to putaway the finished product to the warehouse.
The Warehouse Management (WM) system is interfaced to the SAP Production Planning (PP) application component to replenish kanban stock to production supply areas.
To activate kanban in WM, you need to take the following into consideration in the kanban control cycle:
In addition to the storage location, you need to enter the WM data to include the warehouse number, storage type as a kanban interface (storage type 150 in the standard system) and the storage bin.
You define the strategy for the kanban replenishment under Production → Kanban → Replenishment strategy → Define stock transfer strategy in the SAP Implementation Guide.
To provide kanban replenishment from a WM warehouse to production you
Workers must explicitly request kanban replenishment either manually using the PP system or by scanning a bar code.The system generates 1 transfer requirement with 1 item for each kanban container.
The WM transfer requirement number is noted in the kanban itself. From the kanban, you can display the corresponding transfer requirement (TR). The WM data (storage type, storage bin) defined in the control cycle are copied into the TR.
You process the TR like any normal TR in WM by creating and confirming a transfer order for it.
Once you confirm the transfer order (TO), the system updates the kanban in PP by setting the status to "full".
Option: TO Confirmation in Production
As an alternative to confirming the TO, the confirmation of the replenishment can take place in the kanban. If you set the status of the kanban to "full", the system confirms the corresponding TO automatically.
If the TO cannot be processed in the background in WM (for example, zero stock check is required), the system displays an error message and the kanban is marked accordingly in the system. If this occurs, you must confirm the TO manually in WM and correct the kanban in PP. This kind of discrepancy can be prevented by organizing working procedures in such a manner that it does not occur.
Carry out a stock transfer
After the replenishment has been processed in WM, a stock transfer results between the WM storage location and the kanban storage location. The system can process this stock transfer automatically when the TO is confirmed or you can process it manually by selecting PostChange _ Inventory management _ Stor.loc. to stor.loc. from the WM menu bar.
The Transfer Requirement Header
When you display the transfer requirement header, the following information is of significance:
Handling Cancelled Kanbans
If you cancel a request for kanban replenishment in production, there are several possible conditions and appropriate actions that may be necessary in PP and/or WM depending on the circumstances. The following procedure table provides the information on what you should do when a kanban is cancelled in PP.
If you cancel a transfer requirement for which no transfer order has been generated, the system deletes the reference to the kanban. The kanban indicator in the transfer requirement is deleted. In the kanban, the transfer requirement number and the status of the kanban container is reset. Also, when you delete the transfer requirement, the reference to the requested replenishment is removed from the kanban.
Material Staging for Repetitive Manufacturing
Direct, operation-based picking using pick parts and crate parts has the following disadvantages in a repetitive manufacturing environment:
Due to the disadvantages of staging materials using pick parts, it is necessary to also support material staging using release order parts.
Advantages of staging release order parts:
Various Views of the Pull List
In the initial view of the pull list, the system examines the individual components from the Inventory Management view, that is, at the storage location level. When calculating the missing parts quantity for the individual components, the total requirements of the selected dependent requirements are checked against storage location stock.
From the WM view, it is not precise enough to examine a production area at warehouse level since the warehouse usually also contains several other production areas, storage areas for reserved stock / central replenishment locations.
A detailed view of the stocks in individual supply areas is not necessary for the pick items since the request is always made for the complete production quantity - independent of stock already at the production line. The situation for the release order parts, that is for quantity-dependent staging, is quite different. Here, quantities to be provided are planned depending on the quantity actually available at the supply area. This stock is compared with the requirement quantities.
Another view was integrated into the pull list to allow a detailed display of the stock and requirement situation within the WM warehouse and thus make it possible to selectively carry out WM staging for release order parts.
The following information is included in this display:
Depending on these values, you can then initiate WM material staging.
The choice of the selection type influences which types of WM material staging are supported in the pull list. However, the pick parts can be staged via RS headers/planned orders but not with the current BOM explosion. The release order parts, on the other hand, can also be staged if the current BOM is used for calculating the dependent requirements.
WM material staging via production orders is not possible from the pull list. Note the following in the subsequent selection screen for selection according to RS headers/planned orders:
In the pull list, the system simply compares current stocks with the requirements determined via the selection to calculate the missing parts quantity. No dynamic availability check is carried out. This is valid at storage location level in the main view as well as at supply area level (storage bin stock) in the release order part view.
Therefore, for a correct display of the missing parts situation of a component at the storage location or supply area, you must process all requirements that exist here simultaneously.
Example which would produce misleading results
The following selection is correct:
When accessing the pull list the second time, the second request should leave the beginning of the production period open so selecting all requirements up to 20 November. Now, the total requirement is 150. As a transfer requirement for 100 pieces already exists, the system should created a new request for 50 pieces.
Staging Release Order Parts for Repetitive
To describe changes in procedure and explain how to supply release order parts to production, we will start from the screen "Pull List for RS Header / Planned Order" in the PP system.
The system displays the pull list collective overview with the total quantity of materials required (at the storage location level) next to the missing quantity that is still needed for manufacturing. On this screen, the materials that are relevant to material staging in WM are listed with a staging indicator.
The system displays the WM Material Staging dialog box. From this dialog box, you can carry out material staging for pick parts and release order parts. You have three options:
If you choose Online and more than one production supply area (PSA) is involved, the system displays a second dialog box from which you can select one or more PSA. After you have selected the PSAs, the system displays an overview screen for WM material staging of release order parts. On this screen, for each production supply area (PSA), the system displays the requested quantities, the quantities for which a transfer requirement has already been created, the available quantity in the production storage bin and the quantity in reserve storage for the individual material components. You can manually change the quantity to be supplied and additional information for the creation of the transfer requirement, such as the time and date for material staging.
As soon as you have modified the requirement quantity to meet your requirements, choose WM material staging to initiate material staging for the PSA. To process additional PSAs, choose Edit → Next PSA. When you choose Save, all previously initiated material staging transactions are saved and the system returns you to the WM Material Staging dialog box.
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Sap Wm Tutorial
Warehouse Management Guide
Warehouse Structure In The Warehouse Management System
Planning And Monitoring
Basic Stock Management
Hazardous Materials Management
Wm Interface To Quality Management
Stock Transfers And Replenishment
Posting Changes In Wm
Putaway And Picking Strategies
Storage Unit Management
Interfaces To External Systems
Mobile Data Entry
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