SAP PP Routing3

SAP Routing Routing is defined with list of activities/operations which are required to perform & in whichsequence and machine it has to perform and what are activity time required in order to produce anassembly or semi-finished product.Let consider the below Industrial example. Gears Manufacturing Industry which follows variety of processes likecasting, forging, extrusion, powder metallurgy, and blanking. Each operations are performed in adifferent machines i.e. casting process uses Furnace and Molding Machines and Forging uses hammerforging machines etc. Routing for gear is defined as following sequences with machines and time.Casting-> forging-> extrusion-> powder metallurgy-> and blanking.Furnace/Mold-Hammer forging Hydraulic press- Die press CNC MachineControl Key in Routing Operation: We have discussed about the control key in work center tutorial. Control key from work centerwill be copied to Operation when we creating Routing. Depends upon control key System understandthat whether the particular operation need to be scheduled and capacity and costing need to becalculated or not.Here the detail about the control key about each fields is explained.

Control key definition in OP00 If this indicator marked system schedule the operation using operation time, formula (fromwork center) and Production order quantity.i.e system calculate start date/start time and finishdate/time. If it is not marked system consider the operation as only for information.This indicator is set only when capacity need to be calculate for the operation. System uses schedulingcalculation from the previous Indicator to calculate capacity. We cannot use this Indicator withoutscheduling Indicator activated. This Indicator is only activated when there is an Inspection need to be done after this operationand its results are need to be recorded. Example, before furnace operation, Analyze of charge materialcomposition and recording it against that operation using Inspection characteristics. Automatic goods movement (GR-Goods receipt) of an assembly will be posted when thisoperation is confirmed. Generally This Indicator will be assigned to the final operation.

When Shop floor paper is printed from production order system uses this Indicator fromoperation whether this operation need to be included in time ticket or not If this Indicator is activated, system Identify that rework can be occur in this operation so thatautomatic calculation of yield quantity at the time confirmation will not happen. For the rework quantityentered in operation no automatic GR will happen even though we activate automatic Goods receiptindicator. It must be posted manually These indicators are considered by the system when order is confirmed and print is triggered atthe of Order relase.Operation with the relevant Indicators will be printed in the shop floor Cost for this operation will be calculated using operation details, Order quantity and costingformula from work center. Let say a particular operation (let say die press) is performed outside the manufacturingpremises by vendor. In this case we have to activate the system will generate Purchase requisition forthis operation.

Operation with external processed will be scheduled based on lead time entered in the operation.If you want system to ignore lead time and schedule as per standard values (setup, Machine and labortime) activate schedule external operation Indicator.When mile stone confirmation is selected here system will confirm the preceding operationsautomatically.Confirmation required will be selected when you want operator must confirm the operation and enterthe relevant operation details.We can also restrict user not to enter operation details at the time of confirmation.

Structure of the Routing:Routing has different levels in its structure and different type of data are maintained in each levels. 1. Header 2. Sequences 3. Operation 4. BOM Components 5. QM Inspection characteristics 6. PRT Assignment 7. Trigger point assignment

Creation of RoutingRouting creation in CA01Header Details of Routing:Routing header detail contains information about Routing status, Usage, validity period, Lot size etc.Usage and Status: Usage decided for which application the routing can be used. i.e. Production or PlantMaintenance or all Applications etc. Status can be active and inactive. If routing is created with incomplete data and later user wantto update the missing data, it can be kept with status “Inactive”. So that it cannot be used by the systemuntil he make it active.

Routing Usage & Status in routing Header detailsRouting usage selection- Routing headerStatus:

Routing Status in routing Header detailsValidityThis Start date and end date for the routing which decides its validity period.Sequences in Routing:We have THREE sequences in routing 1. Standard sequences 2. Parallel sequences 3. Alternate sequences Production process operations which are carried out one after another is defined in the sequence. Standard sequence is a linear and simple sequence created in routing. When there is a possibility of an alternative operation or procedure for the standard sequence operation is defined in Alternative sequences.

When there is possibility of an operation which can be performed at the same time with main operation in standard sequence is defined in Parallel sequences.NOTE: 1. We have Routing and rate routing which are used in Discrete and repetitive manufacturing process respectively. 2. In routing we can use Alternate and Parallel sequences where as in rate routing we can only use parallel sequences.Examples from Industries:Consider the previous example of gear manufacturing where the standard sequences is as followsFurnace/Mold-Hammer forging Hydraulic press- Die press CNC Machine In this let say we have 2 Hammer forging machine which are used for depends upon the tonnageoperated. When tonnage is less than 100 TONs business uses Forging Machine 1(FM1) and if it is greaterthan 100 TON they use Forging Machine 2(FM2).In this case Alternate sequence is created with lot size100 TON to Maximum TON it can be operated with work center FM2When order is created less than 100 TON system uses standard sequencesFurnace/Mold-Hammer forging FM1  Hydraulic press- Die press CNC MachineWhen order is created more than 100 TON system uses standard sequencesFurnace/Mold-Hammer forging FM2  Hydraulic press- Die press CNC MachineLet say we have 2 die press which can be operated parallel can be defined as Parallel sequences Die press 1Furnace/Mold-Hammer forging Hydraulic press-Die press 2 CNC MachineOperation Details:Operation details contains 1. work center in which operation need to be perform 2. Operation description

3. Time required (Activity time) to perform the operation for the Base quantity 4. Interoperation times. 5. Additional Information for operation which system uses for scheduling and other purposes.Routing Operation OverviewControl Key selection in Operation OverviewInput all Operations in sequences with work centers on which It performed

Assigning Component to the Operation When a routing is created for an assembly, system will copy its Bill of material to it. Duringproduction process all the BOM item might be consumed at the first operation itself or few componentscan also be consumed at the later operations. SAP uses this information to post the Goods issueautomatically during backflush when operation is confirmed. By default system assign all thecomponents to the FIRST operation.Procedure:Click on and select the component you want to assign

Allocate BOM Components to OperationHere for example purpose I have added only below components in BOM and need BARSTOCK, DUCTILEIRON and CAST IRON in furnace operation and rest in die press stage. 1. BARSTOCK 2. Cast_Iron 3. Ductile Iron 4. PLASTIC RESINSSelect components which you want to assign to the Furnace operation (here first 3 components) andclick on

Click on Button to display all associated operations then select the required operationto which you want to assign.

First 3 components are assigned to Operation 0010

Plastic resin is assigned to the operation ‘050’ i.e. die pressExample Business case:The following raw materials are used in Gear Manufacturing which are components of its BOM.Bar StockCast IronDuctile IronForgingsGear BlanksGear SteelNear-net ForgingsOther Gear MaterialsPlastic ResinsPlastic Stock Forms

Powder Metal MaterialsTool SteelOperation sequences:Furnace/Mold-Hammer forging Hydraulic press- Die press CNC Machine Here not all materials are required and consumed at the start of operation (i.e. furnace andmolding).There are few items which are consumed in subsequence operations also. Like powder metalmaterial and tool steel required in die press. If no component assignment is done, system will assign it tofirst operation by default.To create Sequences click onBy default standard sequences will be createdSequence Overview in Routing

To click parallel or alternate sequences click onSequence Overview – Alternate sequence creationChoose relevant (alternate seq.) radio button and press enterIt asks operation after which you want to branch and return before which operation

Sequence Details in RoutingSelect operation from which you want to craete alternate operation.Let say here we are creatingAlternate sequence for hydraulic press for lot size more than 10 TONS

Sequence details ScreenThen click Operation to maintain alternate Operation that you want

Operation details for Alternate sequencesYou can see this as graphical layout by clicking in sequence overview screen

Sequence Overview-Graphical displayHere click onSequence Overview-Graphical display

QM Inspection Characteristics: When quality inspections are required to carry out during the manufacturing process,Quality Inspection characteristics has to be assigned for the relevant operations. This Inspectioncharacteristics called as in process Inspection chractertics. When an operation assigned with Inspectioncharacteristics is confirmed an Inspection Lot will be generated and Quality person will enter resultrecording.Click on after selecting the operation and assign suitableInspection characteristics.Assignment of QM Inspection characteristicsPRT Assignment: PRT (Production resources/tools) which are used for testing during production, can be assignedto the corresponding Operations in routing/Inspection characteristics.PRT can be an any of the below types 1. Material PRT 2. Equipment PRT 3. Document PRTEach PRT has its own behavior and usage. When you want to measure wear and tear of the tools usedfor treating, we can create it as equipment PRT.A material PRT can be procured, also keep it in stock and we can track its value and quantity at any time.We need valid material master for this. (Transaction MM01)

Equipment production resources and tools are serviced at regular intervals. We need valid equipmentmaster for this. (Transaction IE01)An instruction or guide for manual testing can be attached as document PRT.We need valid documentmaster info record for this. (Transaction CV01n)Click on in operation overview after selecting operationAssignment of PRT to an OperationSelect suitable PRT (Material or equipment or Document) you want to assign suitable master then save.Trigger Point Assignment: Trigger points are assigned to an operations in a routing to trigger certain functions in theproduction order.The below are some of the common functionalities used for trigger point ✓ Release succeeding operations ✓ Release up to stop indicator ✓ Release preceding operations ✓ Create order by copying ✓ Insert reference operation set ✓ Start workflow task (for example, send mail to a user)The detailed functionality of trigger points and its functionality is explained in next tutorial.

Other Operation Specific Details used Routing:Apart from this details, there are some information which can be maintained at Operation level whichprimarily controls “Scheduling” and “Capacity”. Here some important information alone explained.Select the operation for which you want to maintain the operation specific details.Routing Operation Overview (CA01)Operation details in CA01

Routing Operation details in CA01/CA02 Reduction strategy controls scheduling of an operation when its production start date and enddate are not within the Basic dates. This topic is explained in detail in next tututarial.Inter operation time also considered by the system at the time of scheduling which was explained intutorial “PP Scheduling” and also you can find relationship between Reduction strategy andInteroperation time in next tutorial.Splitting section in Routing Operation details If required split indicator is activated, system uses “Number of Individual capacity’ in workcenter at the time of scheduling. (Refer work center tutorial)Number of Splits entered here will be consider by the system to split the capacity load to number ofsplits. If this number of split is not matching with the number of individual capacities entered in thework center, then system schedules with the smaller of these two values.

Minimum processing time entered here will be used by the system after system calculate processingtime by considering number of splits. The system will make sure that the processing time calculated willnot drop below this value during splitting.Rate routing vs routing: • Rate routing has same behavior and structure as routing, but in Rate routing there is no Alternate sequence. • Routing will be generally used in Discrete manufacturing whereas rate routing will be used in repetitive manufacturing.