Rapid Mart Implemntation Suit

7/31/2019 Rapid Mart Implemntation Suit

1/33

Rapid Mar t s pac k ages XI 3 .2 fo r SAP so lu t ionsManufacturing Suite

Rapid Marts Implementation Highlights

October 2009


2/33

SAP AG 2009. All rights reserved. / Page 2

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.


3/33


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


4/33


Agenda

1. Internal OrdersDefinitionSAP solutions ArchitectureInternal Orders Dimension & Hierarchy

2. Routings

3. BOMs (Bills of Material)

4. MTBR / MTTR


5/33


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


6/33


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


7/33


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)


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.


8/33


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


9/33 SAP AG 2009. All rights reserved. / Page 9

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


Note: Only AUFK is usedin the Dimension



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


AFPO(Order Item)



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!



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





AFPO(Order Item) Note: AFPO not used!

ServiceOrder Fact

Order Category30



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)




AFPO(Order Item) Note: AFIH not used!

ProductionOperationFact

Order Category10

AFVC(Operationswithin an Order)

AFVV(Quantities, dates,

values in the operation)

Order Operations



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)




AFPO(Order Item) Note: AFPO not used!

ServiceOperationFact

Order Category30

AFVC(Operationswithin an Order)

AFVV(Quantities, dates,

values in the operation)

Order Operations



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



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





AFPO(Order Item) Note: AFPO & AFKO not

used!

ServiceConfirmationFact

AFRU(Order CompletionConfirmations)

Order

Confirmations



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



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



Agenda

1. Internal Orders2. Routings

DefinitionSAP solutions ArchitectureWhere Used in Rapid Mart (Cross-Reference)


4. MTBR / MTTR



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


OrderOperations

Copy Routings



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



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



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



Agenda

1. Internal Orders

2. Routings


DefinitionSAP solutions ArchitectureRapid Mart AlgorithmRecursive BOMs

BOM ExplosionImplementing Recursive BOM Flag

4. MTBR / MTTR



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



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



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



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


28/33


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


29/33


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


30/33


Agenda

1. Internal Orders

2. Routings


4. MTBR / MTTR (Mean Time Between Repairs & Mean Time To Repair)DefinitionRapid Mart Algorithm


31/33


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


32/33


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


33/33

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

Rapid Mart Implemntation Suit

Documents

Transcript of Rapid Mart Implemntation Suit