Production Planning with SAP S/4HANA
1st Edition
Published on 28. March 2019
Book
Hardback
1010 pages
978-1-4932-1795-3 (ISBN)
Description
Allocate your materials, personnel, and machinery with SAP S/4HANA! This comprehensive guide will show you how to configure production planning in SAP S/4HANA for discrete, process, and repetitive manufacturing. Then run those processes using step-by-step instructions. Master production workflows, like batch management, S&OP, demand management, and MRP. With industry examples throughout, this guide is your one-stop shop for PP with SAP S/4HANA!
Highlights:
1) Discrete, process, and repetitive manufacturing
2) Batch management
3) Sales and operations planning (S&OP)
4) Demand management
5) Material requirements planning (MRP)
6) Long-term planning (LTP)
7) Capacity requirements planning (CRP)
8) Early Warning System (EWS)
9) Reporting and analysis
More details
Other editions
New editions
Jawad Akhtar
Production Planning with SAP S/4HANA
Book
09/2025
3rd Edition
SAP PRESS
€99.95
Available immediately
Person
Author
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.
Content
... Acknowledgments ... 27
... Preface ... 29
... Goals of This Book ... 30
... 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 ... 38
1.2 ... Comparison Table of Production Types ... 50
1.3 ... SAP Integrated Business Planning ... 55
1.4 ... Summary ... 57
2 ... Organizational Structure in SAP ... 59
2.1 ... Breaking Down the Structure into Units ... 59
2.2 ... SAP Calendar ... 68
2.3 ... Summary ... 72
Part II ... Production Planning Configuration ... 73
3 ... Discrete Manufacturing Configuration ... 75
3.1 ... Material Master ... 76
3.2 ... Bill of Materials ... 78
3.3 ... Work Center ... 84
3.4 ... Routing ... 95
3.5 ... Production Order Configuration ... 97
3.6 ... Order Type-Dependent Plant Parameters ... 101
3.7 ... Production Scheduling Profile ... 106
3.8 ... Default Values for the Generation of Operations ... 109
3.9 ... Availability Check ... 110
3.10 ... Scheduling ... 116
3.11 ... Reduction Strategy ... 121
3.12 ... Confirmation ... 122
3.13 ... Reason for Variances ... 130
3.14 ... Trigger Points ... 132
3.15 ... Define Print Control ... 132
3.16 ... Background Jobs ... 133
3.17 ... Summary ... 134
4 ... Process Manufacturing Configuration ... 135
4.1 ... Master Data in Process Industries ... 136
4.2 ... Order Type-Dependent Parameters ... 139
4.3 ... Production Scheduling Profile ... 143
4.4 ... Process Management ... 144
4.5 ... Process Messages ... 149
4.6 ... Process Instruction Category ... 155
4.7 ... Control Recipe/Process Instruction Sheets ... 173
4.8 ... Background Jobs ... 177
4.9 ... Process Manufacturing Cockpit ... 179
4.10 ... Summary ... 182
5 ... Repetitive Manufacturing Configuration ... 183
5.1 ... Repetitive Manufacturing Profile ... 184
5.2 ... Scheduling Planned Orders ... 196
5.3 ... Display ... 197
5.4 ... Material Staging ... 199
5.5 ... Global Settings for Confirmation and the Logistics Information System ... 200
5.6 ... Operational Methods Sheet ... 201
5.7 ... Summary ... 202
Part III ... Production Planning Workflows ... 203
6 ... Production Planning for Discrete Manufacturing ... 205
6.1 ... Process Overview ... 206
6.2 ... Master Data ... 207
6.3 ... Production Order Management ... 246
6.4 ... Release Production Order ... 266
6.5 ... Printing ... 269
6.6 ... Material Withdrawal ... 272
6.7 ... Confirmation ... 279
6.8 ... Goods Receipt ... 286
6.9 ... Postprocessing ... 289
6.10 ... Settlement and Completion ... 291
6.11 ... Additional Functions and Information Systems ... 293
6.12 ... Summary ... 298
7 ... Production Planning for Process Manufacturing ... 299
7.1 ... Process Manufacturing Overview ... 300
7.2 ... Master Data in Process Manufacturing ... 302
7.3 ... Characteristics ... 312
7.4 ... Process Management ... 316
7.5 ... Process Order Execution ... 330
7.6 ... Process Management in Action ... 332
7.7 ... Execution Steps ... 343
7.8 ... Process Messages Evaluation ... 357
7.9 ... Process Manufacturing Cockpit ... 359
7.10 ... Summary ... 360
8 ... Production Planning for Repetitive Manufacturing ... 361
8.1 ... Overview ... 362
8.2 ... Master Data ... 365
8.3 ... Material Requirements Planning in REM ... 387
8.4 ... Planning Table ... 390
8.5 ... Material Staging ... 401
8.6 ... Production List ... 405
8.7 ... Confirmation ... 407
8.8 ... Reversals and Scrap ... 417
8.9 ... Costing Activities (Cost Object Controlling) ... 422
8.10 ... Heijunka ... 424
8.11 ... Reporting ... 425
8.12 ... Summary ... 427
Part IV ... Production Planning Tools ... 429
9 ... Batch Management ... 431
9.1 ... Batch Management Overview ... 431
9.2 ... Batch Level and Batch Status Management ... 433
9.3 ... Master Data in Batch Management ... 438
9.4 ... Business Processes of Batch Management ... 443
9.5 ... Batch Determination ... 452
9.6 ... Recurring Inspection and Expiration Dates ... 467
9.7 ... Batch Derivation ... 474
9.8 ... Batch Traceability of Work in Process Batches ... 487
9.9 ... Batch Information Cockpit ... 499
9.10 ... Electronic Batch Record ... 501
9.11 ... Summary ... 503
10 ... Sales and Operations Planning ... 505
10.1 ... Standard Sales and Operations Planning ... 506
10.2 ... Flexible Planning ... 527
10.3 ... Version Management ... 551
10.4 ... Forecasting ... 553
10.5 ... Rough-Cut Planning Profile ... 567
10.6 ... Events ... 572
10.7 ... Mass Processing in Sales and Operations Planning ... 578
10.8 ... Standard Analysis in Flexible Planning ... 581
10.9 ... Summary ... 584
11 ... Demand Management ... 585
11.1 ... Elements of Demand Management ... 586
11.2 ... Strategies for Make-to-Stock Production ... 593
11.3 ... Strategies for Make-to-Order Production ... 605
11.4 ... Strategies for Assemble-to-Order ... 612
11.5 ... Strategies for Planning Components ... 618
11.6 ... Production with Variant Configuration ... 621
11.7 ... Create a Custom Requirement Class ... 624
11.8 ... Business Processes in Demand Management ... 629
11.9 ... Summary ... 641
12 ... Foundations of Material Requirements Planning ... 643
12.1 ... Process Overview ... 644
12.2 ... Deterministic Replenishment Procedures ... 651
12.3 ... Stochastic Replenishment Procedures ... 664
12.4 ... Configuring Material Requirements Planning Types ... 669
12.5 ... Lot Sizing Procedures ... 672
12.6 ... Rounding ... 681
12.7 ... Scrap ... 683
12.8 ... Safety Stock ... 686
12.9 ... Scheduling ... 695
12.10 ... Procurement Proposals ... 700
12.11 ... Configuration Settings for Material Requirements Planning ... 706
12.12 ... Summary ... 711
13 ... Running Material Requirements Planning ... 713
13.1 ... MRP Live ... 715
13.2 ... Stock/Requirements List ... 720
13.3 ... Planning Calendar ... 737
13.4 ... Planning Areas ... 739
13.5 ... Classic Material Requirements Planning ... 744
13.6 ... Types of Planning Runs ... 746
13.7 ... Demand-Driven Replenishment ... 748
13.8 ... Summary ... 783
14 ... Long-Term Planning ... 785
14.1 ... Long-Term Planning Master Data and Planning Data ... 786
14.2 ... Long-Term Planning: Business Process ... 794
14.3 ... Additional Features in Long-Term Planning ... 800
14.4 ... Evaluate Information Systems ... 806
14.5 ... Summary ... 812
15 ... Capacity Requirements Planning ... 813
15.1 ... Process Overview ... 814
15.2 ... Capacity Requirements and Capacity Evaluation ... 817
15.3 ... Finite Scheduling ... 833
15.4 ... Dispatching ... 835
15.5 ... Capacity Planning Table ... 851
15.6 ... Summary ... 858
16 ... Production Planning and Detailed Scheduling ... 859
16.1 ... Configuration ... 860
16.2 ... Master Data in PP-DS ... 866
16.3 ... Business Processes ... 883
16.4 ... Heuristics ... 891
16.5 ... Production Planning Run ... 893
16.6 ... Reporting and Monitoring Apps ... 907
16.7 ... Alert Monitor ... 913
16.8 ... Plan Monitor ... 915
16.9 ... Summary ... 920
Part V ... Monitoring and Evaluating Production Planning ... 921
17 ... Early Warning System ... 923
17.1 ... Overview ... 923
17.2 ... Exceptions ... 925
17.3 ... Set Up Periodic Analysis ... 932
17.4 ... Schedule an Early Warning System ... 935
17.5 ... Triggering an Early Warning System ... 936
17.6 ... Exception Analysis ... 939
17.7 ... Summary ... 942
18 ... Production Planning Reporting ... 943
18.1 ... The Basics of Reporting ... 943
18.2 ... Report Parameters ... 945
18.3 ... Order Information System Reports ... 958
18.4 ... Missing Parts Information System ... 960
18.5 ... Summary ... 962
19 ... Standard Planning Analysis ... 963
19.1 ... Discrete Manufacturing/Production Order ... 964
19.2 ... Process Manufacturing/Process Order ... 970
19.3 ... Repetitive Manufacturing ... 971
19.4 ... Additional Analysis Functions ... 971
19.5 ... Summary ... 975
20 ... SAP Fiori Apps for Production Planning ... 977
20.1 ... SAP Fiori Launchpad and Apps Library ... 977
20.2 ... SAP Fiori Applications ... 979
20.3 ... Summary ... 991
A ... The Author ... 993
... Index ... 995
... Preface ... 29
... Goals of This Book ... 30
... 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 ... 38
1.2 ... Comparison Table of Production Types ... 50
1.3 ... SAP Integrated Business Planning ... 55
1.4 ... Summary ... 57
2 ... Organizational Structure in SAP ... 59
2.1 ... Breaking Down the Structure into Units ... 59
2.2 ... SAP Calendar ... 68
2.3 ... Summary ... 72
Part II ... Production Planning Configuration ... 73
3 ... Discrete Manufacturing Configuration ... 75
3.1 ... Material Master ... 76
3.2 ... Bill of Materials ... 78
3.3 ... Work Center ... 84
3.4 ... Routing ... 95
3.5 ... Production Order Configuration ... 97
3.6 ... Order Type-Dependent Plant Parameters ... 101
3.7 ... Production Scheduling Profile ... 106
3.8 ... Default Values for the Generation of Operations ... 109
3.9 ... Availability Check ... 110
3.10 ... Scheduling ... 116
3.11 ... Reduction Strategy ... 121
3.12 ... Confirmation ... 122
3.13 ... Reason for Variances ... 130
3.14 ... Trigger Points ... 132
3.15 ... Define Print Control ... 132
3.16 ... Background Jobs ... 133
3.17 ... Summary ... 134
4 ... Process Manufacturing Configuration ... 135
4.1 ... Master Data in Process Industries ... 136
4.2 ... Order Type-Dependent Parameters ... 139
4.3 ... Production Scheduling Profile ... 143
4.4 ... Process Management ... 144
4.5 ... Process Messages ... 149
4.6 ... Process Instruction Category ... 155
4.7 ... Control Recipe/Process Instruction Sheets ... 173
4.8 ... Background Jobs ... 177
4.9 ... Process Manufacturing Cockpit ... 179
4.10 ... Summary ... 182
5 ... Repetitive Manufacturing Configuration ... 183
5.1 ... Repetitive Manufacturing Profile ... 184
5.2 ... Scheduling Planned Orders ... 196
5.3 ... Display ... 197
5.4 ... Material Staging ... 199
5.5 ... Global Settings for Confirmation and the Logistics Information System ... 200
5.6 ... Operational Methods Sheet ... 201
5.7 ... Summary ... 202
Part III ... Production Planning Workflows ... 203
6 ... Production Planning for Discrete Manufacturing ... 205
6.1 ... Process Overview ... 206
6.2 ... Master Data ... 207
6.3 ... Production Order Management ... 246
6.4 ... Release Production Order ... 266
6.5 ... Printing ... 269
6.6 ... Material Withdrawal ... 272
6.7 ... Confirmation ... 279
6.8 ... Goods Receipt ... 286
6.9 ... Postprocessing ... 289
6.10 ... Settlement and Completion ... 291
6.11 ... Additional Functions and Information Systems ... 293
6.12 ... Summary ... 298
7 ... Production Planning for Process Manufacturing ... 299
7.1 ... Process Manufacturing Overview ... 300
7.2 ... Master Data in Process Manufacturing ... 302
7.3 ... Characteristics ... 312
7.4 ... Process Management ... 316
7.5 ... Process Order Execution ... 330
7.6 ... Process Management in Action ... 332
7.7 ... Execution Steps ... 343
7.8 ... Process Messages Evaluation ... 357
7.9 ... Process Manufacturing Cockpit ... 359
7.10 ... Summary ... 360
8 ... Production Planning for Repetitive Manufacturing ... 361
8.1 ... Overview ... 362
8.2 ... Master Data ... 365
8.3 ... Material Requirements Planning in REM ... 387
8.4 ... Planning Table ... 390
8.5 ... Material Staging ... 401
8.6 ... Production List ... 405
8.7 ... Confirmation ... 407
8.8 ... Reversals and Scrap ... 417
8.9 ... Costing Activities (Cost Object Controlling) ... 422
8.10 ... Heijunka ... 424
8.11 ... Reporting ... 425
8.12 ... Summary ... 427
Part IV ... Production Planning Tools ... 429
9 ... Batch Management ... 431
9.1 ... Batch Management Overview ... 431
9.2 ... Batch Level and Batch Status Management ... 433
9.3 ... Master Data in Batch Management ... 438
9.4 ... Business Processes of Batch Management ... 443
9.5 ... Batch Determination ... 452
9.6 ... Recurring Inspection and Expiration Dates ... 467
9.7 ... Batch Derivation ... 474
9.8 ... Batch Traceability of Work in Process Batches ... 487
9.9 ... Batch Information Cockpit ... 499
9.10 ... Electronic Batch Record ... 501
9.11 ... Summary ... 503
10 ... Sales and Operations Planning ... 505
10.1 ... Standard Sales and Operations Planning ... 506
10.2 ... Flexible Planning ... 527
10.3 ... Version Management ... 551
10.4 ... Forecasting ... 553
10.5 ... Rough-Cut Planning Profile ... 567
10.6 ... Events ... 572
10.7 ... Mass Processing in Sales and Operations Planning ... 578
10.8 ... Standard Analysis in Flexible Planning ... 581
10.9 ... Summary ... 584
11 ... Demand Management ... 585
11.1 ... Elements of Demand Management ... 586
11.2 ... Strategies for Make-to-Stock Production ... 593
11.3 ... Strategies for Make-to-Order Production ... 605
11.4 ... Strategies for Assemble-to-Order ... 612
11.5 ... Strategies for Planning Components ... 618
11.6 ... Production with Variant Configuration ... 621
11.7 ... Create a Custom Requirement Class ... 624
11.8 ... Business Processes in Demand Management ... 629
11.9 ... Summary ... 641
12 ... Foundations of Material Requirements Planning ... 643
12.1 ... Process Overview ... 644
12.2 ... Deterministic Replenishment Procedures ... 651
12.3 ... Stochastic Replenishment Procedures ... 664
12.4 ... Configuring Material Requirements Planning Types ... 669
12.5 ... Lot Sizing Procedures ... 672
12.6 ... Rounding ... 681
12.7 ... Scrap ... 683
12.8 ... Safety Stock ... 686
12.9 ... Scheduling ... 695
12.10 ... Procurement Proposals ... 700
12.11 ... Configuration Settings for Material Requirements Planning ... 706
12.12 ... Summary ... 711
13 ... Running Material Requirements Planning ... 713
13.1 ... MRP Live ... 715
13.2 ... Stock/Requirements List ... 720
13.3 ... Planning Calendar ... 737
13.4 ... Planning Areas ... 739
13.5 ... Classic Material Requirements Planning ... 744
13.6 ... Types of Planning Runs ... 746
13.7 ... Demand-Driven Replenishment ... 748
13.8 ... Summary ... 783
14 ... Long-Term Planning ... 785
14.1 ... Long-Term Planning Master Data and Planning Data ... 786
14.2 ... Long-Term Planning: Business Process ... 794
14.3 ... Additional Features in Long-Term Planning ... 800
14.4 ... Evaluate Information Systems ... 806
14.5 ... Summary ... 812
15 ... Capacity Requirements Planning ... 813
15.1 ... Process Overview ... 814
15.2 ... Capacity Requirements and Capacity Evaluation ... 817
15.3 ... Finite Scheduling ... 833
15.4 ... Dispatching ... 835
15.5 ... Capacity Planning Table ... 851
15.6 ... Summary ... 858
16 ... Production Planning and Detailed Scheduling ... 859
16.1 ... Configuration ... 860
16.2 ... Master Data in PP-DS ... 866
16.3 ... Business Processes ... 883
16.4 ... Heuristics ... 891
16.5 ... Production Planning Run ... 893
16.6 ... Reporting and Monitoring Apps ... 907
16.7 ... Alert Monitor ... 913
16.8 ... Plan Monitor ... 915
16.9 ... Summary ... 920
Part V ... Monitoring and Evaluating Production Planning ... 921
17 ... Early Warning System ... 923
17.1 ... Overview ... 923
17.2 ... Exceptions ... 925
17.3 ... Set Up Periodic Analysis ... 932
17.4 ... Schedule an Early Warning System ... 935
17.5 ... Triggering an Early Warning System ... 936
17.6 ... Exception Analysis ... 939
17.7 ... Summary ... 942
18 ... Production Planning Reporting ... 943
18.1 ... The Basics of Reporting ... 943
18.2 ... Report Parameters ... 945
18.3 ... Order Information System Reports ... 958
18.4 ... Missing Parts Information System ... 960
18.5 ... Summary ... 962
19 ... Standard Planning Analysis ... 963
19.1 ... Discrete Manufacturing/Production Order ... 964
19.2 ... Process Manufacturing/Process Order ... 970
19.3 ... Repetitive Manufacturing ... 971
19.4 ... Additional Analysis Functions ... 971
19.5 ... Summary ... 975
20 ... SAP Fiori Apps for Production Planning ... 977
20.1 ... SAP Fiori Launchpad and Apps Library ... 977
20.2 ... SAP Fiori Applications ... 979
20.3 ... Summary ... 991
A ... The Author ... 993
... Index ... 995