SAP PP (Production Planning)

Introduction to SAP PP

Gain a comprehensive understanding of the SAP PP module and its significance in managing production planning and manufacturing processes within organizations. Explore the key functionalities of SAP PP, including master data management, production scheduling, capacity planning, and shop floor control. Understand how SAP PP integrates with other SAP modules such as MM (Materials Management) and SD (Sales and Distribution) to optimize production operations and meet customer demand.

Master Data Management

Dive into master data management in SAP PP, which involves creating and maintaining key master data elements such as materials, work centers, and bills of materials (BOMs). Learn how to configure material master records, work center hierarchies, and routing sequences to represent production resources and processes accurately. Understand the use of BOMs, work centers, and production versions to define product structures, manufacturing processes, and production routings in SAP PP.

Production Planning and Scheduling

Explore production planning and scheduling processes in SAP PP for creating production orders, work orders, and planned orders based on demand forecasts and customer orders. Learn how to generate production schedules, allocate resources, and balance production capacities to meet production targets and deadlines. Understand the use of planning strategies, lead times, and scheduling parameters to optimize production efficiency and minimize production lead times.

Capacity Planning

Delve into capacity planning processes in SAP PP for evaluating and optimizing production capacities to meet production demands and resource constraints. Learn how to perform rough-cut capacity planning (RCCP) and detailed capacity planning to analyze capacity requirements and identify capacity bottlenecks. Understand the use of work center capacities, shift sequences, and production calendars to schedule production activities and optimize resource utilization.

Material Requirements Planning (MRP)

Explore material requirements planning (MRP) functionalities in SAP PP for managing material availability and procurement processes. Learn how to run MRP simulations, generate MRP proposals, and perform MRP evaluations to ensure timely availability of materials for production. Understand the use of MRP controllers, planning horizons, and planning parameters to fine-tune MRP runs and optimize material planning and procurement processes.

Shop Floor Control

Understand shop floor control processes in SAP PP for monitoring and controlling production activities in real-time. Learn how to record production confirmations, goods movements, and production progress using SAP PP transactions and interfaces. Explore functions such as order release, order confirmation, goods issue, and goods receipt to track production orders, update inventory records, and manage shop floor activities efficiently.

Production Execution and Monitoring

Explore production execution and monitoring functionalities in SAP PP for overseeing production processes, monitoring production performance, and analyzing production metrics. Learn how to generate production reports, dashboards, and key performance indicators (KPIs) to track production progress, analyze production variances, and identify opportunities for process improvement. Understand the integration between SAP PP and MES (Manufacturing Execution Systems) for real-time production monitoring and control.

Quality Management Integration

Delve into quality management integration with SAP PP for managing quality inspection processes and ensuring product quality throughout the production cycle. Learn how to create inspection plans, inspection lots, and quality notifications to capture quality defects and deviations during production. Understand the use of quality control points, sampling procedures, and inspection types to enforce quality standards and regulatory requirements in production processes.

Production Orders and Work Centers

Explore the creation and management of production orders and work centers in SAP PP. Learn how to define production order types, control parameters, and scheduling parameters to manage production activities efficiently. Understand the use of work centers, work center categories, and work center hierarchies to represent production resources and capacities. Explore functions such as capacity leveling, work center hierarchies, and work center capacities to optimize production scheduling and resource utilization.

Production Versions and Variants

Delve into production versions and variants in SAP PP for managing product variants, configurable products, and production variations. Learn how to create production versions and variants to represent different product configurations, options, and variants. Understand the use of variant configuration profiles, dependency networks, and variant conditions to generate variant-specific bills of materials (BOMs), routing sequences, and production routings. Explore functions such as variant explosion, variant selection, and variant validation to manage product variants and production variations efficiently.

Batch Management and Serial Numbers

Explore batch management and serial number management functionalities in SAP PP for tracking and tracing production batches and serial numbers. Learn how to configure batch master records, batch classification, and batch determination to manage batch-specific attributes and characteristics. Understand the use of serial number profiles, serial number ranges, and serial number assignment to assign and track unique serial numbers to individual products and components. Explore functions such as batch determination, batch split, and batch status management to ensure product traceability and compliance with regulatory requirements.

Integration with Shop Floor Systems

Understand the integration between SAP PP and shop floor systems for seamless production execution and monitoring. Learn how to integrate SAP PP with manufacturing execution systems (MES), supervisory control and data acquisition (SCADA) systems, and plant floor automation systems. Explore functions such as real-time data acquisition, production data exchange, and shop floor integration protocols to enable real-time production monitoring, data collection, and process control. Understand the benefits of shop floor integration for improving production visibility, operational efficiency, and decision-making.

Lean Manufacturing and Kanban

Delve into lean manufacturing and Kanban functionalities in SAP PP for implementing lean production principles and Kanban-based production control. Learn how to configure Kanban boards, Kanban signals, and Kanban control cycles to manage material flow and production replenishment processes. Understand the use of Kanban cards, Kanban containers, and Kanban rules to trigger production orders and material movements based on demand signals and inventory levels. Explore functions such as Kanban scheduling, Kanban replenishment, and Kanban monitoring to optimize production flow, reduce lead times, and eliminate waste.

Advanced Planning and Optimization (APO)

Explore advanced planning and optimization (APO) functionalities in SAP PP for advanced production planning and scheduling. Learn how to leverage APO modules such as production planning and detailed scheduling (PP/DS), global available-to-promise (GATP), and supply network planning (SNP) to optimize production plans, allocate resources, and manage supply chain constraints. Understand the use of advanced planning algorithms, optimization heuristics, and simulation tools to improve production efficiency, responsiveness, and agility.