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Rapid Mar t s pac k ages XI 3 .2 fo r SAP so lu t ionsManufacturing Suite
Rapid Marts Implementation Highlights
October 2009
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Disc la imer
The information in this presentation is confidential and proprietary to SAP and may not bedisclosed without the permission of SAP. This presentation is not subject to your licenseagreement or any other service or subscription agreement with SAP. SAP has no obligation topursue any course of business outlined in this document or any related presentation, or to
develop or release any functionality mentioned therein. This document, or any relatedpresentation and SAP's strategy and possible future developments, products and or platformsdirections and functionality are all subject to change and may be changed by SAP at any timefor any reason without notice. The information on this document is not a commitment, promiseor legal obligation to deliver any material, code or functionality. This document is provided
without a warranty of any kind, either express or implied, including but not limited to, the impliedwarranties of merchantability, fitness for a particular purpose, or non-infringement. Thisdocument is for informational purposes and may not be incorporated into a contract. SAPassumes no responsibility for errors or omissions in this document, except if such damageswere caused by SAP intentionally or grossly negligent.
All forward-looking statements are subject to various risks and uncertainties that could causeactual results to differ materially from expectations. Readers are cautioned not to place unduereliance on these forward-looking statements, which speak only as of their dates, and theyshould not be relied upon in making purchasing decisions.
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Manufac t u r ing Su i t e Rap id Mar t s fo r SAPso lu t ions : Sourc e Modules
Rapid Mart SAP solutions Module
Plant Maintenance Rapid Mart PM
Production Planning Rapid Mart PP
Project Systems Rapid Mart PS
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Agenda
1. Internal OrdersDefinitionSAP solutions ArchitectureInternal Orders Dimension & Hierarchy
2. Routings
3. BOMs (Bills of Material)
4. MTBR / MTTR
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In t e rna l Orde r sDef ined
In SAP solutions Logistics modules an Order is a task or set of tasks to be performed.
These are called Internal Orders in the Rapid Marts
An Internal Order specifies :Which tasks to performWhat order to perform the tasksWhen to perform the tasksWhat resources are needed to perform the tasks
How the costs of performing theses tasks are to be settled
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In t e r na l Orde r sSAP so lu t i ons Arc h i t e c t u r e
Internal OrderHeader
OrderOperations
OrderConfirmations
Header General Information about the order
Operations Lists specific tasks to be performedThere can be multiple operations in an order
Confirmations Documents actual time tocomplete Operations (tasks)
There can be multiple confirmations for anoperation
Three Tiered Architecture
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In t e r na l Orde r sSAP Arc h i t ec t ure Det a i l s (E/R Diag ram )
This Slide details the SAP solutions tables used for Internal Orders
AFVC(Operations
within an Order)
AFVV(Quantities, dates,values in the operation)
Order Operations
AFRU(Order CompletionConfirmations)
Order Confirmations
AFKO(Order header data PP orders)
AFPO(Order Item)
AUFK(Order Master Data)
Internal OrderHeader
AFIH(Maint. Order Header)Note: Table AFPO (Order Item) The Order Item identifies
the end material produced by the Production Order. In mostcases this is a single material and each Production Order
carries a single Order Item. Thus, we have grouped the AFPO table within the Internal Order Header.
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In t e r na l Orde r sCa t e go r ie s & Rap id Mar t Usage
Internal Orders are categorized in SAP solutions:
Category Description
01 Internal Order (Controlling)
02 Accrual Calculation Order (Controlling)
03 Model Order (Controlling)
04 CO Production Order 05 Product Cost Collector 06 QM Order 10 PP Production Order
20 Network30 Maintenance order 40 Process Order 50 Inspection Lot
60 Personnel Order 70 Shipping deadlines
In Rapid Marts Internal Orders are usedas:
DimensionsHierarchies
Fact TablesDetails follow
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In t e r na l Orde r Dim ens ion & Hie r a r chy
The Internal Order Dimension:
Header Level Order InformationCovers all Order Categories.
It is used in several Rapid Marts
The dimension has an associated hierarchy based on organizing Internal Orders for Cost-based Controlling:
Internal Order DimensionUsed in these Rapid Marts: AP CA GL IA PM PP PS
AUFK(Order Master Data)
Note: Only AUFK is usedin the Dimension
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Produc t ion Orde r Fac t &N et w o r k Or d e r Fa c t
Production Order Fact is a Common Fact TableUsed as Production Order Fact in the PP Rapid Mart (only Order Category 10)Used as Network Order Fact in the PS Rapid Mart (only Order Category 20)
The same Target Table is used in both Rapid Marts
Production Order Fact Aliased as Network Order Fact in PS Universe
AFKO(Order header data PP orders)
AFPO(Order Item)
AUFK(Order Master Data)
Internal OrderHeader
Data Services
ProductionOrder Fact
Order Category10
NetworkOrder Fact(Alias)
Order Category20
Note: Global Variables Inthe Data Services Jobscontrol which Order Categories are loaded
AFIH(Maint. Order Header)
Note: AFIH not used!
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Ser v ic e Orde r Fac t
Service Orders are used only in the PM Rapid Mart
They are also called Maintenance OrdersThey are Header Level Internal Order data
Only Order Category 30 is extracted
Data Services
AFKO(Order header data PP orders)
AUFK(Order Master Data)
Internal OrderHeader
AFIH(Maint. Order Header)
AFPO(Order Item) Note: AFPO not used!
ServiceOrder Fact
Order Category30
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Produc t ion Opera t ion Fac t
Production Operations are used only in the PP Rapid MartThey combine Header and Operation Level DataOnly Order Category 10 is extracted
Data Services
AFKO(Order header
data PP orders)
AUFK(Order Master Data)
Internal OrderHeader
AFIH(Maint. Order Header)
AFPO(Order Item) Note: AFIH not used!
ProductionOperationFact
Order Category10
AFVC(Operationswithin an Order)
AFVV(Quantities, dates,
values in the operation)
Order Operations
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Ser v ic e Opera t ion Fac t
Service Operations are used only in the PM Rapid MartThey combine Header and Operation Level DataOnly Order Category 30 is extracted
Data Services
AFKO(Order header
data PP orders)
AUFK(Order Master Data)
Internal OrderHeader
AFIH(Maint. Order Header)
AFPO(Order Item) Note: AFPO not used!
ServiceOperationFact
Order Category30
AFVC(Operationswithin an Order)
AFVV(Quantities, dates,
values in the operation)
Order Operations
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Ord er Opera t ion Dim ens ion
A Generic Order Operations Dimension is available in the PP & PS Rapid MartsOnly Operation Level Data is used
All Categories are extracted
Data Services
Note: AFVV not used!
OrderOperations
AllCategoriesAFVC
(Operationswithin an Order)
AFVV(Quantities, dates,values in the operation)
Order Operations
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Ser v ic e Conf i r m a t ion Fac t
Service Confirmations are used only in the PM Rapid MartThey combine Header and Confirmation Level Data
Data Services
AFKO(Order header data PP orders)
AUFK(Order Master Data)
Internal OrderHeader
AFIH(Maint. Order Header)
AFPO(Order Item) Note: AFPO & AFKO not
used!
ServiceConfirmationFact
AFRU(Order CompletionConfirmations)
Order
Confirmations
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In t e r na l Orde r Dim ens ionUnive r se Ex am ples
Examples of Internal Order Dimension Usage:
Internal OrderDimension
VendorFinancial Doc.Fact
ReservationFact
CostSummary Fact
FinancialDocumentFact
Material Mvmt.
Fact
Notification
Fact
AP
PM
GL
PS
CA
IA
PP
Network OrderFact
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In t e r na l Orde rAddi t iona l Un ive r se Ex am ples
Internal OrderDimension
ProductionOrder Fact
Network OrderFact
OrderOperationFact
ProductionOperationFact
PP RapidMart
PS RapidMart
Alias of ProductionOrder Fact
Alias of Order OperationDimension as a
Fact
Internal Order as Dimension
joined to Internal Order asFact
In some cases it is advantageous to:Join Internal Order as a Dimension to Internal Order as a Fact
Alias a Dimension table as a Fact
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Agenda
1. Internal Orders2. Routings
DefinitionSAP solutions ArchitectureWhere Used in Rapid Mart (Cross-Reference)
3. BOMs (Bills of Material)
4. MTBR / MTTR
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Rout ingsDef ined
Routings are a type of Task List with SAP solutionsThey enumerate and describe the tasks to be performed by an Internal Order
Routings are the master data for Internal Order OperationsExample:
Routings are set up as separate master data in SAP solutions A set of routings is assigned to a BOM (Bill of Materials)These routings are copied into a Production Order as Operations
BOM
AssignedRoutings
Create ProductionOrder
Internal OrderHeader
OrderOperations
Copy Routings
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Rout ingsSAP so lu t ions Arc h i t ec t u re ER Diagr am
PLNTY,PLNNR,PLNAL
PLNTY,PLNNR,PLNAL
PLKO(Task ListHdr)
PK:PLNTYPLNNRPLNALZAEHL
PLFL(Task list -Sequences)
PK:PLNTYPLNNRPLNALPLNFLZAEHL
PLNTY,PLNNR,PLNKN
PLNTY,
PLNNR,PLNAL,PLNFL
MAPL(Assignmentof Task ListsTo Materials)
PK:MATNRWERKSPLNTYPLNNRPLNALZKRIZZAEHL
PLNTY,PLNNR,PLNAL
PLAS(Task list -selection of operations/activities)
PK:PLNTYPLNNRPLNALPLNFLPLNKNZAEHL
PLNTY,PLNNR,PLNAL,PLNFL,
PLNKN
PLPOTask list -operation/activity)
PK:PLNTYPLNNRPLNKNZAEHL
PLKZ(Task List -Main Hdr)
PK:PLNTYPLNNRPLNAL
PLMZ
(Allocate BOMto Operations)
PK:PLNTY
PLNNRZUONRZAEHL
FKs:PLNAL
PLNFLPLNKN
FKs:STLTY
STLNRSTLALSTLKN
PLAS: Allows a set of RoutingOperations (PLPO) to be assignedto more than one Routing Header(PLKO)
Note: SAP Column NameDescriptions are available in the
ATL or SAP solutions
Legend:PK = Primary KeyFKs = Foreign Keys
Arrows indicate:ONE MANY
Relation between tables
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Rou t ings SAP so lu t i ons Arch i t ec t u r eConnec t ions to Produc t ion Order s , BOMs & Mate r i a l s
PLNTY,PLNNR,PLNKN
MAPL(Assignmentof Task ListsTo Materials)
PK:MATNRWERKSPLNTYPLNNRPLNALZKRIZZAEHL
PLAS(Task list -selection of operations/activities)
PK:PLNTYPLNNRPLNALPLNFLPLNKNZAEHL
PLNTY,PLNNR,PLNAL,PLNFL,PLNKN
PLPOTask list -operation/activity)
PK:PLNTYPLNNRPLNKNZAEHL
PLMZ(Allocate BOMto Operations)
PK:PLNTYPLNNRZUONRZAEHL
FKs:PLNALPLNFLPLNKN
FKs:STLTYSTLNRSTLALSTLKN
AFVC(Operationswithin an Order)PLNTY,
PLNNR,PLNAL,PLNFL,PLNKN
STKO(BOM Header)
STLTY,STLNR,STLKN
MARC(Material Plant Data)
MATNR,WERKS
MAPL: Allows more than oneRouting for a Material (MARC)
PLAS: Also allows a set of RoutingOperations (PLPO) to be assigned to
more than one Production Order(AFVC)
PLMZ: Allows a set of RoutingOperations (PLPO) to be assigned to aBOM (STPO)
STPO(BOM Item)
STLTY,STLNR,STLAL
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Rout ingsWhere Use d in PP Rapi d Mar t Cro ss-Refer enc e
Fact Tables Dimension Tables
SAPTable
RoutingBOMFact
RoutingLine Fact
RoutingMaterial
RoutingOperation
RoutingSequence
Routing
MAPL X
PLAS XPLFL X X
PLKO X X
PLKZ X
PLMZ XPLPO X X X
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Agenda
1. Internal Orders
2. Routings
3. BOMs (Bills of Material)
DefinitionSAP solutions ArchitectureRapid Mart AlgorithmRecursive BOMs
BOM ExplosionImplementing Recursive BOM Flag
4. MTBR / MTTR
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BOM (Bi l l s o f Mat er ia l ) Def ine d
BOMs are a hierarchy in SAP
They represent the recipe for construction or assembly of one material from othersThe Material constructed is the parent material or assembly
The Materials used are the component materialsThe BOM ID represents the relationship between Parent and Component
They can be represented as a hierarchy diagram
A
B C
1.1 1.2
Parent Material
ComponentMaterials
BOM ID:
The BOM ID is a composite key. The two mostimportant pieces are:
BOM ID (identifies parent)
BOM Item (Identifies components)
Example: 1.2 = BOM Number . BOM Item
BOM ID
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MAST(Material To BOMLink)
PK:MATNRWERKSSTLANSTLNRSTLAL
STPO(BOM Item)
PK:STLTYSTLNRSTLKNSTPOZ
STKO(BOM Header)
PK:STLTYSTLNRSTLALSTKOZ
STKO.STLNR =MAST.STLNRSTKO.STLAL = MAST.STLALSTKO.STLTY = MSTKO.LOEKZ =
STAS(BOM ItemSelection)
PK:STLTYSTLNRSTLALSTLKN
STASZ
STPO.STLTY = STKO.STLTYSTPO.STLNR = STKO.STLNRSTPO.LKENZ =
STAS.STLTY = STPO.STLTYSTAS.STLNR = STPO.STLNRSTAS.STLKN = STPO.STLKNSTAS.LKENZ =
BOM Bac k groundArch i t ec t u r e i n SAP so lut i ons
The BOM architecture represents aSINGLE LEVEL material BOMExploded (Multi-Level) BOMs are NOTstored in the SAP solutions system
Parent Material
Component
Materials
Arrows indicate a One to Many Relationship
One Many
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Rap id Mar t A lgo r i t hmProduc t ion BOM Fac t
The Top Level Material is usually the final productproduced for sale.
The Rapid extracts PRODUCTION_BOM_FACTas a single level Bill of Materials
It joins the tables on the previous slide into a singlefact table that looks like this:
AT 4.1
B
Ax
D2.1 2.2
A
B
C
1.1
1.2
D
I J
3.1 3.2
Top LevelMaterial
X = RecursiveBOM Flag
BOMID
BOMItem
ParentMaterial
ComponentMaterial
RecursiveBOM Flag
1 1 A B
1 2 A C
2 1 B A x
2 2 B D
3 1 D I
3 2 D J
4 1 X A
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Rec ur s ive BOMsDefined
B
Ax
2.1
A
1.1
A BOM is Recursive When A Parent is also its own Component.
Using our example the relationship A B A is recursiveSAP indicates the Recursion with one of two flags:
STPO.REKRI = X BOM is Recursive (set by system)STPO.REKRS = X Recursion Allowed (set by user)
In our example, recursion is shown as the x on Node AxIn the Rapid Mart, the RECURSIVE_BOM_FLAG is set on tablePRODUCTION_BOM_FACT
If either STPO.REKRI or STPO.REKRS = X, the value will be 1. Thisindicates a Recursive BOMOtherwise the value will be 0 (zero). This indicates a Non-RecursiveBOM
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BOM Ex p losion Bu ild s a H ier a r c hy o f a l lBOMs for a Top Level Mat er ia l
B
Ax
A
B C
D
I J
C
T
1.1
1.2
2.1 2.2
1.1 1.2
3.1 3.2
4.1
Top LevelMaterial When we explode the BOM, we stop if theRecursive BOM Flag is set
This prevents Circular Dependency (InfiniteLoop)
In the Rapid Mart, the Hierarchy FlatteningTransform is used to explode BOMs
PRODUCTION_BOM_FACT is the input
PRODUCTION_BOM_EXPLOSION_FACTis the outputBOMs are exploded HorizontallyBOMs are exploded up to 6 levels deep
Customization is required if deeper levels or Vertical explosion is needed.
Circular Dependency
X = RecursiveBOM Flag
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BOM Ex plos ionIm plem en t ing Rec urs ive BOM Flag
The Recursive BOM Flag on table Production BOM Fact is not implemented in the releasedversion of the Production Planning Rapid Mart.
As delivered, the Rapid Mart can fail with a Circular Dependency error in BOM Explosion.This error only occurs if you have recursive BOMs in your SAP solutions system
Please consult the embedded PDF File BelowOr consult SAP Note 1420573Both give full directions on how to implement this important feature.
Double Click to seePDF
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Agenda
1. Internal Orders
2. Routings
3. BOMs (Bills of Material)
4. MTBR / MTTR (Mean Time Between Repairs & Mean Time To Repair)DefinitionRapid Mart Algorithm
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MT BR / MT TRDefined
MTBR and MTTR are measures in Plant Maintenance that record how long equipment or Functional Location is available (or not available) for use in your enterprise
MTBR = Mean Time Between Repairs (also called Up-Time)MTTR = Mean Time To Repair (also called Down-Time)
In the Plant Maintenance Rapid Mart, the measures are calculated from the Notification Facttable
Thus, loading Notifications is a prerequisite for these measures An intermediate Staging table is used to facilitate the calculation
MTBR MTTRFact
NotificationFact
Data Services
MTBR MTTRStage Data Services
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MT BR / MT TRRap id Mar t A lgo r i t hm
MTBR / MTTR are only calculated for notifications meeting these criteriaStatus = CompleteNot marked for deletionMust have Malfunction Start Date populated
Must have Malfunction End Date populatedMust have an assigned Functional Location or Equipment.
MTBR MTTR Stage: Data is pivoted to segregate Notifications with Functional Locationsfrom those with Equipment:
Notifi-cationID
Malfunc-tion Start
Malfunc-tion End
ObjectID
ObjectFlag
ObjectStart UpDate
100 11/18/2004 11/22/2004 Pump EQ 8/1/2002
101 5/10/2006 5/12/2006 Pump EQ 8/1/2002
102 9/15/2009 9/20/2009 Pump EQ 8/1/2002
103 2/2/2005 2/14/2005 Factory FL 6/1/2000
104 7/1/2007 7/14/2007 Factory FL 6/1/2000105 4/16/2008 4/20/2008 Factory FL 6/1/2000
EQ = EquipmentFL = Functional
Location
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MT BR / MT TRRap id Mar t A lgo r i t hm
Chronological Ordering of Notifications for eachEquipment or Functional Location is crucial
Next step populates MTBR MTTR FACT from thestage table
Notifi-cationID
Malfunc-tion Start
Malfunc-tion End
ObjectID
ObjectFlag
ObjectStart UpDate
UpTime(Days)
DownTime(Days)
100 11/18/2004 11/22/2004 Pump EQ 8/1/2002 840 4101 5/10/2006 5/12/2006 Pump EQ 8/1/2002 534 2
102 9/15/2009 9/20/2009 Pump EQ 8/1/2002 1222 5
103 2/2/2005 2/14/2005 Factory FL 6/1/2000 1707 12
104 7/1/2007 7/14/2007 Factory FL 6/1/2000 867 13
105 4/16/2008 4/20/2008 Factory FL 6/1/2000 277 4
For 1 st Notification for each Equipment or Functional Location
Up Time = Malfunction Start Object Start Up
For 2 nd through last Notification for each Equipment or FunctionalLocation
Up Time = Malfunction Start Current Notification MalfunctionEnd Previous Notification
For all Notifications
Down Time =Malfunction End Malfunction Start