SAP PP Interview Question and Answer

Part 1:

1) Explain what is SAP PP?

SAP PP process is related to production planning of a company and it encompasses all activities like MRP (Material Requirement Planning), BOM (Bills Of Material), Routing, Capacity planning, etc. but mainly it contains two segments

Material Planning: Material requirements planning, long term planning,
Execution Planning: Creation of production order, workflow, conformations, technical completion and good movement

2) Mention what are the production process in SAP?

There are three types of production process in SAP

Discrete Manufacturing
Repetitive Manufacturing
Production- Process Industries

3) List out the activities carried out in Production Planning?

Activities involved in Production Planning includes

Processing material master
Creation of Bill of Material
Displaying work center and routing
Maintaining planning calendar
Maintaining production lot
Maintaining quota file
Defining range of coverage profile and profile for safety time
Defining MRP views

4) Explain what is Routing in SAP PP?

Routing in SAP PP is referred to a list of activities which are required to produce any material. For example, when you do cost estimation for the material, the system triggers the relevant routing and activity rates for all those described in routing. Which will helpful to calculate the processing cost in product costing.

5) What are the steps of Production Execution Process?

Production Execution steps include

Converting planned order to production order
Releasing the production order
Goods issue for production order
Confirmation of production order
Goods receipt against production order

6) What are the reports generated in product cost controlling information system?

Product Cost Controlling information system generates information for following areas

Product cost planning
Cost object controlling with the subcomponents
- Product cost by period
- Product cost by order
- Product cost by sales order
- Costs for intangible goods and services
Actual costing / Material Ledger

7) Explain what is “work center” in SAP PP and what is the use of Data in Work Centers?

“Work Centers” are business objects in SAP-PP that is used in task list operations (routings, maintenance task lists, inspection plans) and work orders.Data in work center is used for

Scheduling: Formulas and operating time are entered, so that the duration of an operation can be calculated
Costing: Formulas are entered so that the costs of an operation can be calculated
Capacity Planning: The available capacity and formulas for capacity requirements is entered
Simplifying operation maintenance: Various default values can be included in the work center

8) What is the use of MRP PP evaluations?

This role contains a function for evaluating the MRP result. This function can be used to find information about the availability of material and to identify any material shortage situation.

9) Mention what is the purpose of using Capacity Planning?

Capacity Planning supports planning in all phases

Long term rough cut planning
Medium term planning
Short term planning

It can be integrated with various SAP applications like SAP-SD, PP, PP-SOP, PP-LTP, PP-SFC, etc.

10) Explain how can you create production order without routing and BOM?

Without BOM and routing you can create a production order by changing the config in OPL8 ( order type dependent parameters) as routing optional. When we try to create an order using C001 it may ask for a sales order.

11) Explain what happens to planned after it has been converted into production order?

When planned order is converted to the production order, the planned order are offset by production order. The planned order reference can be seen in the production order.

12) Mention what is the difference between stock transport order and stock transfer order?

Stock transfer order: It is referred to the transfer of stock for the usage in the same company
Stock transport order: It is referred to the change of title of stock in the name of the buyer

13) Explain what is PRT (Production Resource Tools) in SAP PP?

PRT (Production Resource Tools) are moveable operating objects used to perform repeated activities in plant or production maintenance, for example, documents such as drawings or programs for which document management functions are used. Various other PRT components include

Engineering drawings
Jigs
Fixtures
Measurement Instruments

14) Explain how to create PRT master records?

To create PRT master records you have to follow the following steps

Choose logistics/Accounting -> Project System -> Basic data -> Master data -> Production resources and tools -> Create
The initial screen for creating a PRT appears
Enter a number for the PRT and choose continue
The basic data screen appears
Maintain the basic data
Choose Goto -> Defaults and enter the default values
Save the PRT

15) Mention what is the t-code for changing production order and to display production order?

T-code to change the production order = C002

T-code to display the production order = C003

16) Explain what is PLM (Product Lifecycle Management) in SAP PP and what is the use?

It is a collection of solutions with which you digitally create, maintain and make product information, available in the whole company and for the entire life cycle of the product.

PLM provides you the function with which you do following things

The workplace is an open portal in the world wide web and allows you to access all application and information that you need to work with all external and internal business partners
It can link with other internet applications like program management, change and configuration management and engineering collaboration.

17) In SAP-PP what are the costing parameters?

In SAP-PP, the costing parameters are as below

Work Center: Activity types and the formulas, cost center
Routing: The time, activity types

18) In cost controlling information system mention the fields that are listed in the list screen of the report?

Following fields are listed in the list screen of the report

Key Figures
- Costing/MM
- %Costing/MM
- Revaluation
- VarCstRuns
- %VarCstRuns
Basic data
Valuation
Cost component group 1/ Cost component group 2
CostCompGr(fix)1 / CostCompGr( fix)2

19) Explain what is the use of SAP Material View and list out other parameters where SAP Material View is applicable?

SAP Material View is an SAP object that not only hold name of the material, but various other information related to material like

Material production related information
Material planning related information
Material sales related information
Material purchase related information
Material storage and warehousing related information
Material costing and Accounting related information
Material batch specification information

20) Mention what are the types of Master Views for Production and Planning?

For production and planning types of Master Views are

SAP MRP1 View
SAP MRP2 View
SAP MRP3 View
SAP MRP4 View
SAP Work Scheduling View

21) Mention how MRP (Material Requirement Planning) types are classified?

MRP types are classified in two leagues

Materials for consumption based planning
Planning based on demand

22) Mention what are the keyfields found in MRP View 1?

MRP views 1 are mostly maintained for production purposes.

General Data
MRP Procedure
Lot size data

23) List out the basic procedure for dispatching operations in capacity leveling?;

For dispatch operations basic procedure includes

Either the user determines the date of dispatch or else it is specified by scheduling
A dispatching sequence needs to be determined if several operations need to be dispatched
The systems checks for
- The dates to which operations are to be dispatched
- The work center to which operations are to be dispatched
Finite scheduling is performed
Operation check is performed
Status for the operation is set as “dispatched.”
System carries out midpoint scheduling

24) Explain what is the need of MRP list if the stock requirement list is already given?

MRP list displays the result of the last planning run, changes that occurred between planning runs are ignored in the MRP list. While contrary to this, in the stock or requirement list all changes that occurred in the stock, issues and receipts are displayed by the system.

25) Mention what are the t-codes for creating, changing and summarizing BOM?

BOM transaction codes for

Creating BOM= CS01
Changing BOM= CS02
Summarized BOM=CS13

26) Mention what is the use of t-code CS20 in BOM?

With t-code CS20 you can do Mass changes to BOM like

Change the item data
Creating new material
Replacing it with another material

Part 2:

Q1. Explain what is SAP PP?

Ans:

Material Planning: Material requirements planning, long term planning,

Execution Planning: Creation of production order, workflow, conformations, technical completion and good movement

Q2. Mention what are the production process in SAP?

Ans:

There are three types of production process in SAP

Discrete Manufacturing
Repetitive Manufacturing
Production- Process Industries

Q3. List out the activities carried out in Production Planning?

Ans:

Activities involved in Production Planning includes

Processing material master
Creation of Bill of Material
Displaying work center and routing
Maintaining planning calendar
Maintaining production lot
Maintaining quota file
Defining range of coverage profile and profile for safety time
Defining MRP views

Q4. Explain what is Routing in SAP PP?

Ans:

Q5. What are the steps of Production Execution Process?

Ans:

Production Execution steps include
Converting planned order to production order
Releasing the production order
Goods issue for production order
Confirmation of production order
Goods receipt against production order

Q6. What are the reports generated in product cost controlling information system?

Ans:

Product Cost Controlling information system generates information for following areas

Product cost planning
Cost object controlling with the subcomponents
Product cost by period
Product cost by order
Product cost by sales order
Costs for intangible goods and services
Actual costing / Material Ledger

Q7. Explain what “work centre” in SAP PP is and what is the use of Data in Work Centers?

Ans:

“Work Centers” are business objects in SAP-PP that is used in task list operations ( routings, maintenance task lists, inspection plans) and work orders.Data in work center is used for

Scheduling: Formulas and operating time are entered, so that the duration of an operation can be calculated
Costing: Formulas are entered so that the costs of an operation can be calculated
Capacity Planning: The available capacity and formulas for capacity requirements is entered
Simplifying operation maintenance: Various default values can be included in the work center

Q8. What is the use of MRP PP evaluations?

Ans:

This role contains a function for evaluating the MRP result. This function can be used to find information about the availability of material and to identify any material shortage situation.

Q9. Mention what is the purpose of using Capacity Planning?

Ans:

Capacity Planning supports planning in all phases

Long term rough cut planning
Medium term planning
Short term planning

It can be integrated with various SAP applications like SAP-SD, PP, PP-SOP, PP-LTP, PP-SFC, etc.

Q10. Explain how can you create production order without routing and BOM?

Ans:

Q11. Explain what happens to planned after it has been converted into production order?

Ans:

When planned order is converted to the production order, the planned order are offset by production order. The planned order reference can be seen in the production order.

Q12. Mention what is the difference between stock transport order and stock transfer order?

Ans:

Stock transfer order: It is referred to the transfer of stock for the usage in the same companyStock transport order: It is referred to the change of title of stock in the name of the buyer

Q13. Explain what is PRT (Production Resource Tools) in SAP PP?

Ans:

Engineering drawings
Jigs
Fixtures
Measurement Instruments

Q14.Explain how to create PRT master records?

Ans:

To create PRT master records you have to follow the following steps

Choose logistics/Accounting -> Project System -> Basic data -> Master data -> Production resources and tools -> Create
The initial screen for creating a PRT appears
Enter a number for the PRT and choose continue
The basic data screen appears
Maintain the basic data
Choose Goto -> Defaults and enter the default values
Save the PRT

Q15. Mention what is the t-code for changing production order and to display production order?

Ans:

T-code to change the production order = C002
T-code to display the production order = C003

Q16. Explain what is PLM (Product Lifecycle Management) in SAP PP and what is the use?

Ans:

It is a collection of solutions with which you digitally create, maintain and make product information, available in the whole company and for the entire life cycle of the product. PLM provides you the function with which you do following things The workplace is an open portal in the world wide web and allows you to access all application and information that you need to work with all external and internal business partners It can link with other internet applications like program management, change and configuration management and engineering collaboration.

Q17. In SAP-PP what are the costing parameters?

Ans:

In SAP-PP, the costing parameters are as belowWork Center: Activity types and the formulas, cost centerRouting: The time, activity types

Q18. In cost controlling information system mention the fields that are listed in the list screen of the report?

Ans:

Following fields are listed in the list screen of the report

Key Figures
Costing/MM
%Costing/MM
Revaluation
VarCstRuns
%VarCstRuns
Basic data
Valuation
Cost component group 1/ Cost component group 2
CostCompGr(fix)1 / CostCompGr( fix)2

Q19. Explain what is the use of SAP Material View and list out other parameters where SAP Material View is applicable?

Ans:

SAP Material View is an SAP object that not only hold name of the material, but various other information related to material like

Material production related information
Material planning related information
Material sales related information
Material purchase related information
Material storage and warehousing related information
Material costing and Accounting related information
Material batch specification information

Q20. Mention what are the types of Master Views for Production and Planning?

For production and planning types of Master Views are

Ans:

SAP MRP1 View
SAP MRP2 View
SAP MRP3 View
SAP MRP4 View
SAP Work Scheduling View

Top of Form

Bottom of Form

Q21. Mention how MRP (Material Requirement Planning) types are classified?

Ans:

MRP types are classified in two leagues

Materials for consumption based planning
Planning based on demand

Q22. Mention what are the keyfields found in MRP View 1?

Ans:

MRP views 1 are mostly maintained for production purposes.

General Data
MRP Procedure
Lot size data

Q23. List out the basic procedure for dispatching operations in capacity leveling?;

Ans:

For dispatch operations basic procedure includes Either the user determines the date of dispatch or else it is specified by scheduling A dispatching sequence needs to be determined if several operations need to be dispatched The systems checks for The dates to which operations are to be dispatched The work center to which operations are to be dispatched Finite scheduling is performed Operation check is performed Status for the operation is set as “dispatched.” System carries out midpoint scheduling

Q24. Explain what is the need of MRP list if the stock requirement list is already given?

Ans:

Q25. Mention what are the t-codes for creating, changing and summarizing BOM?

Ans:

BOM transaction codes for

Creating BOM= CS01
Changing BOM= CS02
Summarized BOM=CS13

Q26. Mention what is the use of t-code CS20 in BOM?

Ans:

With t-code CS20 you can do Mass changes to BOM like

Change the item data
Creating new material
Replacing it with another material

Q26. Can we create Production order without bom and routing?

Ans:

yes we can create a production order without BOM & routing.Change the Config in OPL8 ( order type dependent parameters)as routing optional. But it may ask for a sales order when we try to create order using CO01

Q27. What is the difference between by-product and co-product and how do you differentiate them in a BOM?

Ans:

In case, of Co-product costs are settled with an apportionment structure. In case, of By-product the price of this by-product is credited to the order or the material stock account of the lead material being manufactured. Co-Product as well as by-product are defined as BOM Components/Items. Both of them have negative quantities. ( Not all negative quantity items fall under these categories!). When BOM is created for FERT, you can see one indicator in COMPONENT DETAILS screen for co-product. You need to define the co-products with this special indicator

Q28. What are some important tables used in PP (Production Planning)?

Ans:

For orders:

CUAFVD dialog structure for order headers and items
AFPO – Order item
AFFLD Order: Dialog table for order sequences (AFFL)
MOPER Operation for production order
KBED Capacity requirements
AFRU Order completion confirmations
RESB Reservation/Dependent Requirements
AFFHD Structure of PRT’s in orders
SOPER Sub-operations
SAFRU Sub-operation confirmations
SKBED Capacity requirements for sub-operation
MRP table is MDTB.

For PI:

CAUFV – AFVC Operation within an order
AFFT Order Process Instructions
AFFV Order process instruction values

Some other tables of interest:

PLKO, MAPL, PLAS.

Q29. What is the difference between PP and PP-PI? Which one is better and how?

Ans:

PP–> Prodction Planning mostly used for descrete type of industries , where at the time of confirmation the output issure to be fixed. eg Automobile PP- PI–> Production Planning for Process Industries , here mostly used for the typical chemical industries , as the Yield is not fixed due to chemical reaction yield values can be varied to noticable extent. Eg X+Y =Z some 10 kg of X

and 1 KG of Y givs yiled that is Z of 10 Kg only.

Q30. What are the costing parameter?

Ans:

The costing Parameters are the following Work center : Activity types and the formulaes,cost center Routing : the time ,activity types In Production order dependent parameters we are defining the Variant ,result analysis key,settlement profile In the controlling i.e in KP 26 we will be defining the rates per hour depending on the rates it will reflect the cost caluculating from the routing..

Q31. What structure do your BOMs have? How many levels are there?How many components are there on each level?

Ans:

BOM IS A multilevel,we can assign bom level by level cs11,level 1 bom header material assembly levelcontains components which also have bom contains level 2 bom sub assembly level

last lower level is level 3 components level

Q32. How to attach a drawing for a material to BOM ? Is it possible ?

Ans:

Yes, you can attach a drawing. First create a document using Transaction Code “CV01N – Create Document”. Attach your drawing in that document. The system will generate a document number. Assign this document in the BOM with item category D. Report in Long Term Planning – You use long term planning for your customers, what they need are very simple, just to calculate future requirements for 1 or 2 years.

Q33. Are there any reports in SAP to list of material requirement from LTP ?

Ans:

You need a list of material requirement from long term planning result for each item. Use MS70 then use MCEC.

Q34. If there are some errors in goods movements, and less stock of material consumed, how can i solve that problem in SAP?

Ans:

According to me COGI is basically a SAP standardised system which will tell you that what is the error in some cases it can rectify it too.But if the entry is done manually by MB1A, MB1B, MB1C you have to bring back or cancell the movement or move the stock to desired material and then refresh COGI.

Q35. What is a ‘BOM’?

Ans:

A ‘BOM (Bill of Material)’ is nothing but a structured list of components (with the object number, quantity, and unit of measure) that go into the making of a product or an assembly. Depending on the industry sector, they may also be called recipes or lists of ingredients. The structure of the product determines whether the bill of material is simple or very complex.

Q36. What are all the ‘Technical Types of BOM’?

Ans:

There are two ‘Technical Types of BOM’ supported in SAP:

Variant BOM
Material BOM

Q37. Explain why their is need of production version?

Ans:

In production version, we assign the BOM and ROUTINGcombination. And in case of alternate BOMs , it clears whichalternative bom has to be selected automatically.

Q38. Differentiate ‘Variant BOM’ from ‘Multiple BOM.’

Ans:

While a ‘Variant BOM’ groups together several BOMs that describe different objects (for example, different models of a car) with a high proportion of identical parts, a Multiple BOM groups together several BOMs that describe one object (for example, a product) with different combinations of materials for different processing methods.

The Variant BOMs are supported for the following BOM categories:

Material BOMs
Document structures
Equipment BOMs
Functional location BOMs
Multiple BOMs are only supported for Material BOMs.

Q39. Define ‘BOM Group.’

Ans:

A ‘BOM Group’ is a collection of BOMs that lets you describe a product or a number of similar products. The value in the BOM group field uniquely identifies the BOM group. You can use the BOM group as an alternative way of accessing the BOM. A BOM group comprises either all the alternatives of a multiple BOM or all the variants of a variant BOM.

When you create a BOM group, the system checks the special characters you use. Apart from the usual alphanumeric characters, you can use the following special characters: ‘-’,‘/’,‘_.’ You cannot use blanks.

Q40. Explain what is the meaning of exploding a BOM?

Ans:

it is the process of multiplying the requirement by the usage quantity and recording the appropriate requirements throughout the product tree

Q41. What are the ‘BOM Categories’ Supported by SAP?

Ans:

The following are the various Categories of BOM:

Equipment BOM
Material BOM
Sales Order BOM
Document Structure
Functional Location BOM
WBS BOM

Q42. What are all the different manufacturing scenarios in pp?

Ans:

There are different scenarios in SAP PP module.

Make to stock
Make to order
External processing (Subcontracting)
Rework processing
Prodcution in another plant

Q43. How to delete a group of products that was created in screen MC84 ?

Ans:

Delete the members in the product group and then archive the product group in transaction SARA, object=MM_MATNR. (The product group is created as a material master record with material type PROD and this record is deleted in SARA.)

Q44. Do you have different BOMs for a material in different plants?

Ans:

generally we have following BOMs

Product Tree
Parent- component relationship
Multilevel Bill
Multiple Bill
Single Level Bill
Indented bill

Q45. Tell me the planning steps for 100 products?

Ans:

CK11n is used for standard cost estimation.to run that we have to run ck24 also.

Q46.How to configure the planning calendar for the ATP calculation where goods are shipped every other working day?

Ans:

Use Transaction MD25 and define calculation rule for every other working day. Check the lot size settings in OMI4 and maintain relevant data in MMR.

Q47. We have two different production lines with different operations. One production line works 5 days a week and the other 7 days a week. The factory calendar is assigned to the plant for 5 days a week. This calendar is checked when MRP is run. How can we assign 5 day a week and 7 days a week against a factory calendar to the related resources? Is it possible to have two types of calendars?

Ans:

Assign factory calendars to the work centers.

Q48. We have a BOM – ‘A’ with two packing materials ‘X’ and ‘Y’. For 1000 units of ‘A’, 1 packing material of ‘X’ is required and for 50 units of ‘A’, 1 packing material of ‘Y’ is required. Base quantity of ‘A’ is defined as 1000. How can I define ‘X’ & ‘Y’ or in fact ‘A’?

Ans:

Make the base quantity of ‘A’ as 5000. The resulting component quantities would be 5 of ‘X’ and 100 of ‘Y’.Work Centers

Q49. Can we have more than 6 standard values in standard value key?

Ans:

One way to achieve this is to create another operation step using the same work center. However this shall be with a control key that is not a milestone. When the milestone operation is confirmed, the previous operations up to the next milestone are automatically confirmed. To get the desired number of standard values , all the ‘non milestone’ steps can be built depending on the need.

Q50. Can we use same routing for materials undergoing the same process/operations? Can we avoid separate routing for each and every material produced?

Ans:

Presume that there are 50 products and the fabrication shop uses a set of 10 machines. If all these products use the same settings of the machines, Reference Operation Sets (task list type S) can be setup for common processes that use the same work centers. However costing, scheduling and capacity will be affected if each product has different setup time and Reference Operation sets can not be used.A routing for each material number ( type N or R) has to be set up and within that routing, the Reference Operation Set can be used.However, you can by try utilizing the KMAT material and product variants invariant configuration to avoid separate routing for each material.

You may create a routing group. Go into routing creation and enter the plant and the group name. If you want you may name the group, else name is assigned by internal counter). Create the routing with the work centers, operation times, etc. Go to the “Header overview” screen and click on the “Mat Alloc” screen. Fill in the blanks with all the material masters that use this routing.

Q51.Scheduling times can be defined in the material master record by;

Ans:

entering the in-house production time. This value can be updated from the routing by the system.# entering the setup, tear down, processing, and interoperation times. If these values are maintained, the system determines the in-house production time on the basis of lot size.

Q52.How do you get the system to update this value from the routing?

Ans:

In routing, carry out scheduling. Go into the routing operation overview and follow Extras -> Scheduling -> Results. The pop-up window displays the scheduling data. At the bottom there is a pushbutton to copy the scheduling data to the material master Check this push button to update master data.

Q53. We have deleted a group key in an operation in routing and the same does not appear for this routing (CA02). But we noticed that entries are maintained in table PLPO and the deletion indicator is not set. How does the system remember this deletion of group key?

Ans:

You may look at the tables PLKO, MAPL and PLAS. Sales & Operations Planning

Q54.We defined SOP in months. However, during SOP transfer to demand management, our independent requirements are appearing in weeks. How can we correct this from weeks into months ?

Ans:

Check transaction OMPA for general split. OMPS – based on the MRP group. Ensure that MRP group assigned to the material. Delete any allocations in these tables.

Then periods will be transferred to Demand Management with the same splits as in SOP. Also, check whether the value of period is set as “month” at your plant level in Transaction ‘OMP7’ Demand Management

Q55.Sales quantities in SOP for certain days are transferred into Demand Management and are shown as planned independent requirements. We need to keep the settings in SOP and change the periods in Demand Management? We would like to have a rolling horizon, for ex: the following 4 weeks on a daily basis, after that on a monthly basis. What is the best way to do this?

Ans:

Use the automatic period split function.

Q56.We have a lot of size procedure here which is creating more order proposals. How do you set the limit value for the maximum number of MRP order proposals per date in IMG?

Ans:

Under customization, try materials management->consumption based planning->maintain all plants

Q57.What is the difference between “planned consumption” and “Unplanned consumption”? Can safety stock calculation be done on either of these?

Ans:

While customizing movement types (OMJJ) it is defined as to which set of consumption values gets posted during the material movement. For some, it may always be the total consumption and for some, it is always the unplanned one and for some, it is dependent on whether the issues were done with reference to a reservation ie., a planned consumption. The way these consumption values are taken into account in MRP is defined in the customizing of MRP types. For Reorder point planning (VM) the total consumption is used to calculate the safety stock and the reorder point.

For Forecast-based planning (VV) the total consumption is used to build the forecast which will be used to compile the order proposals. For Deterministic MRP (PD) the unplanned consumption is used to calculate the forecast which in turn is added to the actual demand.

Q58.We want the system to run a single level MRP automatically on receipt of sales order. How to configure triggering event based MRP?

Ans:

This can only be run if the material master has planning strategy 41 (made-to-order) in the MRP2 view. We need to run for other MRP types. We have to create a user exit in the sales order processing (VA01) to start MRP based on data from our sales transaction.

Q59.We have an assembly ‘A’ using a subassembly ‘B’. ‘B’ in turn uses raw material ‘C’. Item ‘A’ is an MPS and is duly marked in Material Master. Item ‘B’ and ‘C’ are marked as ‘PD’. When demand for ‘A’ is entered and MPS is run , upto which level the requirements are taken care of?

Ans:

MRP can be run depending on your requirement. For example: Single Item / Single Level from MPS – Transaction Code MD42 – Only the top MPS item ( ‘A’ in this case) is planned and dependent requirements will be passed to MRP item ( ‘B’ ) . Run MRP, Transaction MD02 on ‘B’ to plan it and all MRP items below. Single Item / Multi Level from MPS – Transaction Code MD41 – All levels are planned – A, B & C Total Planning from MPS online or background – Transaction Code MD40 or MDBS

Without marking the checkbox ” Process MRP materials” is like case ( 1) above and with the checkbox marked is like case (2 ).Production Orders

Q60.We get an error message “Control parameters for scheduling not defined” while creating test production Orders. Why?

Ans:

Before you attempt creating Production orders, configure your

Order types- Transaction Code OPHJ
Order type Dependent parameters – Transaction Code OPL8
Backorder Scheduling – Transaction Code OMIH
Scheduling Levels – Transaction Code OMIF

Q61.We are trying to create Purchase Requisition from MRP run. We have material, info Record, Source list, Demand in place. MRP is always creating plan order. Why?

Ans:

Check the procurement type in MRP view of material master. Check ‘Create Purchase requisition’ indicator while running MRP. If you want purchase requisitions to be created in the opening period, select the for MRP control parameter ‘create purchase requisitions’ as ‘1’.

Q62. what is the option “Documented goods movements” on Selection of Individual Object Lists (transaction code CO28)?

Ans:

Use Transaction code OPL8 to customize by choosing the order type, select all the checkbox under “Documentation of goods movements” at the bottom of the page. Create a new Production order, make GI to it, and run the report.

Q63.We would like to have a report/inquiry that would indicate variances (materials, material quantities) between material recipe and actual process orders. We tried ME2M but this gives us a list of purchasing documents and not the consumption deviation. Where can I get such consumption deviation (master recipe Vs. Process> Orders)?

Ans:

Do a data collection first.Menu Path – Accounting->Controlling->Product cost acctg->Process mfg->Information system->Cost object hierarchy->data collection Then, Accounting->Controlling->Product Cost Accounting->Order Related Production->Information System Choose Report Period Costing – Target/Actual production variance

Q64.We have two components ( ‘X’ & ‘Y’ ) in a production order in a process oriented production process. When 50 numbers of component ‘X’ are issued, we need the system to automatically issue 100 numbers of component ‘Y’ based on the ratio of 1 to 2. Where do I specify these ratios?

Ans:

You can define the ratio in BOM and material may be issued with reference to BOM.

Q65.We have two storage locations are ‘0001’ and ‘0600’. Default storage location in Process order is always ‘0001’ What determines this default location?

Ans:

Look into OSS notes: 100757, 63493, 96262, 87843, 82033, 64946. The Storage location as configured in the Supply area has the highest priority.

Q66.We need to do GI of components to production order using Back-flush. The component stock is managed in Batches. The Batch to be back-flushed

Ans:

With the following settings, the batches are selected the moment the production order is released.

Set up batch determination the way that the batches in batch selection are sorted the right way. e.g. sorted by expiry date
Use automatic batch selection in disp view.
Ensure that the components are allowed to be back-flushed (material master/ work center) is selected by FIFO from the issue storage location.

Q67.We want to report on several status combinations like each order that has status ‘Not deleted’ and ‘Not technically completed’. What set up is required?

Ans:

Check transaction CO28. In the selection screen note the possible selection ‘System Status’. You can select TECO for technically complete an DLT for deleted from the list. Select the Excl. indicator also. You may also try transaction CO26 (Logistics -> Production -> Production control -> Control -> Information systems -> Order Info System -> Object overview). Before executing the transaction report, combinations of statuses can be selected or exclude them.

Q68.How can we shut off the “automatic costing indicator” and the “automatic scheduling indicator” which go on when the production order is released?

Ans:

For “no automatic costing” follow the IMG path Production -> Production orders ->Master data -> Order – >Define order type dependent parameters Select the order type for which u automatic costing is not required. In the controlling settings, select “no automatic costing” For “no automatic scheduling”, follow the IMG path: Production ->Operations – >Scheduling -> Define control parameters Select the order type and go to details. Deselect ” automatic dates ” Alternatively, you can find indicators in the control key, which is in the routing. Transaction OPL8 gives you costing indicators (Order type dependent parameters), and OPJU (control table for scheduling) gives some scheduling options.

Q69.How can I use variable size items?

Ans:

For example, consider an item A with ‘kg’ as base Unit Of Measurement(UOM) and ‘m3’ as stock keeping/issue unit. Conversion factor is 1kg = 2.4 m3.In the BOM of ‘B’ ,number of A required are specified (say 5).Specify the 3 variable dimensions i.e. length, width & thickness- say 2000mm X 3000mm X 4mm = 0.024 m3As per BOM – ‘B’ , the quantity of A required is 0.024 X 5 = 0.120 m3

If a production Order is released for 15 numbers of ‘B’ , the quantity of variable size unit will be 1.20 m3. You can change the length, width or thickness in the production order & check the resulting variable size item quantity. At the same time, this requirement can be seen in ‘kg’ in stock/requirement list.

Q70. Can MRP be carried out for one particular level of a bom ( Level code: 0001/0002 etc).

Ans:

Yes it can be done by running for specific materials (Single Material Single Level)

Q71. How Requirements (PIR, Sales Order, Customer Requirement) are reduced after they are produced?

Ans:

Reqmts are reduced automatically after Delivery is made to the Particular Order

(In case of Strategy 11, the PIRs are consumed after the GR for Production Order)

Q72. Can’t one material be assigned to more than one operation in a routing?

Ans:

One material from a BOM CANNOT be assigned to different Operations. It can be done by defining the material for so many times as required in the BOM

Q73. How to insert an inspection checkpoint at the end of an operation?

Ans:

If in process sample is to be defined, assign inspection type 03 in the Material Master.Then create MICs and assign them in the Routings. System automatically generates the Inspection Lots

Q74. Where have we to specify the teardown time in one operation?

Ans:

Teardown time can be defined as one of the Standard Parameters…

Q75. How is the process time calculated in a WC when both labour, Machine categories exist?

Ans:

Scheduling is done based on the Capacity Category we define in the Workcenter

Q76. How to create object dependencies in a BOM FOR A CONFIGURABLE MATERIAL?

Ans:

Go to Extras -> Object Dependency -> Assign For this, you need to create Characteristics and Class (of Class Type 300) earlier

Q77. Can anybody explain to me why work scheduling view is required for semi-finished and finished products? (Because we’ll mention all details in MRP views)

Ans:

We need to maintain working scheduling view in order to make that finished or semi-finished goods available for production as we assign production scheduler and production scheduler profile in this view, if not maintained conversion of planned order to production will not be possible.

Q78. Why are all withdrawable, non-backflush components not always issued on the list?

Ans:

In addition to the reservation item criteria (movement allowed, non-backflush, requirement quantity > 0 and BAPIs in Production Order and Process Order FAQ- BAPIs in Production Order and Process orderHow are the BAPIs BAPI_PRODORD_GET_DETAIL (determining detail data for production orders) and BAPI_PROCORD_GET_DETAIL (getting detail data for process PP-PDC

Q79.What is PLM in SAP PP?

Ans:

PLM in SAP PP is a collection of solutions with which you digitally create, maintain and make product information, available in the whole company and for the entire life cycle of the product.

Q80. Find the scenario and give the result: A, B, C are employees, where A, B will get basic, HRA, DA. C gets Basic and DA. How to group for the allowances?

Ans:

Allowances are paid depending on his gradation and even wages are also paid on this criteria if AB is paid bas, hra, and DA then take three wage types and assign to the ES Grouping and don’t give HRA wage type to C.

Check basic salary of inda and ALlowances in Indian payroll thoroughly, bcos first of all v have to understand this first and then you have to decide the emp sub-groupings.

Q81. What is the use of INFO GROUPS?

Ans:

The info type group (commonly known as Infogroup) guarantees that during the personnel action, all information needed for the business processes is stored. The Infogroup is processed when you perform a personnel action. – An Infogroup exists in the standard system for every personnel action type. – In Customizing for Personnel Administration, you can tailor the make-up of the various info groups to the requirements of your company. – You can define info groups as user-group dependent. Infogroup’s are used in Personnel Actions to define a set of sequential info types that you would be using while performing an action. For example, when you hire, you would want to use IT0000,0001,0002,0006,0007,0008, etc in a sequence- in a particular order. To define an Infogroup for this purpose which contains all these info types, their order of execution and the user groups it is applicable for. Then you assign this Infogroup to the action that you had defined.

Q82. Explain the uses of the simple maintenance interface?

Ans:

Simple Maintenance is used when Staff assignments and reporting structure are to be changed. There are three main areas in Simple Maintenance. Each area contains particular maintenance functions, depending on whether you want to edit organizational structure, staff assignments or task profiles. For Organizational Management users, Simple Maintenance is best used to establish the basic framework in organizational plan development. For complete, detailed editing of individual organizational objects in your organizational plan (editing particular positions or organizational units, for example), we recommend that you switch to Info-type Maintenance. Simple maintenance uses a tree structure, which allows you to create a basic framework for organizational plans, using streamlined procedures. In this way, we can create organizational and reporting structures step by step.

Q83. We defined SOP in months. However, during SOP transfer to demand management, our independent requirements are appearing in weeks. How can we correct this from weeks into months?

Ans:

Check transaction OMPA for the general split. OMPS – based on the MRP group. Ensure that MRP group assigned to the material. Delete any allocations in these tables.

Then periods will be transferred to Demand Management with the same splits as in SOP. Also, check whether the value of period is set as “month” at your plant level in Transaction ‘OMP7’

Q84. How are Time management and payroll are integrated?

Ans:

TM MGMT and Payroll are integrated into ways are time data is collected from the info type 0007 and these hours are taken in basic as Number of hours worked or utilized, and even with time evaluation and last with schemas integration. X000 schema carries xt00 and these data can be transferred between other modules.

Part 3 :

1) Compare SAP PP with Oracle?

S.No	SAP PP	Oracle
1	It has the latest features on guiding the planning processes for the production	Not all but a few features are outdated
2	Routing is possible in all the modules in SAP PP	Routing is not possible in all the modules
3	The latest version has been released	No update on the release of next version

2) What do you mean by the term production?

It is basically the manufacturing of goods and services or shaping them in a form that is required by the users. There are certain things that the product or the services has to go through and each step aims to make the product or services better than the previous. Production can be in-house or outhouse.

3) What do you mean by the term Batch production? Do you think the SAP PP is good enough to be trusted for the same?

For organizations, it is not always easy to build a project easily. They, therefore, build it up in small slots which are also known as a batch. Each section of the product is built by a specific team with a similar objective. Batch production simply makes sure of error elimination at the right time. It is one of the best production methods that are widely adopted. SAP PP has dedicated features for this and it is possible for the users to keep an eye on all the batches with the help of this tool.

4) Can you name a few steps in the production execution process which are of prime importance?

The very first thing is converting the planned order into a production one. The next thing about which users should pay attention to is releasing the production order post which the goods are issued. The receiver then acknowledges the same and finally, the receipts are matched.

5) How the SAP PP tool is good enough to be considered for production planning in an effective manner?

This tool assures a diverse array of benefits to those who go for it. It brings a very large number of benefits and can simply enable the users to keep up the pace with all the right strategies in a delightful manner. Some of the best things about this tool are spotlighted below.

It makes sure of effective utilization of resources
It enables a business to capture the market in a very delightful manner
Organizations can make sure of a steady flow of production
Resources can easily be estimated with it
The overall productivity of the labor can easily be enhanced
It always makes sure of optimum inventory
It simply facilitates the quality improvement
A lot of production cost can be saved easily

6) What are the factors that can help you in preparing the Production Budget?

This can be done by paying attention to various factors which are as below:

The very first thing to consider is the quality of the product
2. The overall number of units to be manufactured in a specific time period
3. The demand for the product
4. The overall number of resources to be deployed in the production team
5. Time period of the project
6. Any special requirements

7) Do you think SAP PP is useful when it comes to getting the authorization of the product?

Yes, it is very beneficial in this matter. It simply makes sure of all the standards are followed during the pre and post-production. This is exactly when that enables businesses in assuring the authorization of the product in a very reliable manner.

8) Is it possible to get a product ready for inspection through the SAP PP?

The SAP Production Planning tool is a powerful one. It simply guides the users on adopting various strategies and methods that are useful in proper production without compromising with the quality. SAP PP tool help eliminating various errors and bugs that affect the quality. Therefore, it contributes a lot to proper production planning and getting a product ready and friendly with the inspection process in a reliable manner.

9) What do you mean by the term planning horizon?

It is basically a defined time period of a production plan. Depending on the type and nature of the product, its overall duration can vary largely

10) Does Resource allocation have a role in the proper implementation of the Product planning approach?

Resource allocation is one of the prime necessities for the same. It simply makes sure the right employees and human resources are assigned for tasks that are complex and need additional attention. With proper resource allocation, it is possible for the organizations to avoid several hassles that declare their presence in the production.

11) What is Productive capacity in SAP PP and how it is useful for the organization?

It is basically a feature in the SAP Production Planning tool which guides the users about the upper limit of production they can handle with the overall number of resources they have.

It simply helps to determine the organizations about the exact time, resources, planning, investment, and other needs they have to accomplish a production process easily.

12) Compare in-house and out-house production processes?

In-house production is when an organization or a business develops its products or services in its own arena through its own tools, skills, and technology. In-house production needs huge costs in the initial stage but it offers large-scale benefits for the long run. Out-house production means getting a product or a service ready by an organization from a third-party source. This is also known as outsourcing. This is done when an organization lacks the basic or the advanced requirement for production such as required skills, experience, technology, investment, and so on. Both in-house and out-house have their own pros and cons associated with them both together.

13) Can you name a few strategies that can help to make product planning more superior without investing additional money?

Assuring the level of production required with resources already existing
2. Determining the future needs of the buyers/users
3. Factory load determination
4. Setting and maintaining delivery orders
5. Scheduling the entire plan

14) How a mass production is a good approach according to you?

It is basically the manufacturing or production of a very large amount of units. Not all the products are required to be produced in bulk actually except the ones which are higher in demand. The users are free to simply make sure or favorable outcomes through this method of production because bulk production always helps in cost-cutting.

15) Name the important activities that are a part of any production process?

These are processing the material master and creating the bill, displaying the work center, defining MRP, range of coverage as well as marinating the quota file.

16) While manufacturing a product, what exactly are the factors that are to be of significant importance? Can SAP PP is useful in helping users following the same?

There are certain things actually which need the close attention of the core management during production processes. A few of them are:

Paying attention to the quality of the product
2. The overall demand
3. Manufacturing policies and standards to be followed
4. Environmental cause
5. Overall usefulness of the product
6. Production authorization

17) How Production planning is related to the material requirement?

The material requirement is actually one of the important principles of production planning. The planners have to make sure that the entire raw material remains available all the time. Generally, they have to make sure of the availability of at least 10 days of stock depending on the type of production. All the orders about the raw material should be placed on time.

18) What according to you are the prime requirements for production planning?

These are the right equipment, workforce, technology, controls, and processes

Q19) What are the various factors to pay attention to in order to avoid errors from the production?

The problems are necessary to be formulated whenever they are traced. The first thing that can help to avoid them is the verification of the inventory with respect to time. All the suppliers should be qualified and organizations must understand the true benefits of investing in quality. With these corrective actions, it is possible to deal with the issues that often declare their presence in the production.

20) What is the role of data which is present in the work centers in SAP PP?

They are loaded with some important data which simply make sure of costing and similar factors. In addition to this, they make sure of proper scheduling of everything. This is useful for calculating the overall duration of an object. Also, it makes sure of capacity planning and performing the operation maintenance manually and easily.

21) What do you know about the Product analysis?

It is basically an approach of testing a product after its development and before its delivery to the customers. Product analysis makes sure of the quality and better customer relations. In addition to this, it enables organizations to save the cost which they have to bear for faulty or wrong product delivery.

22) Can you name the different production processes available in SAP PP?

These are Repetitive manufacturing, Discrete manufacturing, as well as production manufacturing

23) How the production cost can be eliminated? Can SAP PP help in this matter?

There are several methods of cutting the overall cost from a development or a production process. The first thing could be outsourcing the specific or an entire project to another company or an organization that has specialization for the same. Another method is to buying the raw material in bulk and assuring the things are going smooth. One more method that can help in this matter is investing in technology that promises favorable results. The production cost can also be eliminated by adopting various standards of production.

SAP PP is a powerful tool that has some basic features to get the right information and reporting on how the overall production cost can be eliminated.

24) What do you know about Routing in Sap PP?

It is basically nothing but a full-fledged list that provides information on producing any material. It is very beneficial in predicting the overall cost of a project depending on the information stored in it.

25) What is the role of cost controlling information system in SAP PP according to you?

It is responsible for providing information on various aspects that largely matters about product planning. A few objectives of the same are spotlighted below.

Controlling the cost of objects through the subcomponents
2. Maintaining the ledger
3. Cost-cutting
4. Providing information on delivered products

26) What is the significance of work centers in SAP PP?

They are useful in some important operations such as maintenance of the task list, performing inspection, scheduling the tasks and monitoring the overall production.

27) What is the significance of MRP PP evaluation?

It is basically a function in the SAP PP that is beneficial in providing information regarding the overall availability of the material and if there is a quick need of the same in a short span of time.

28) What are the different phases of planning in the SAP PP the users can make use of?

These are Long term. Medium-term and short-term planning. The users are free to simply take decisions regarding the module and the phase they are interested to consider. However, in SAP PP this largely depends on the data and the information availability.

29) Without BOM and Routing, is it possible in the SAP PP to create a production order?

Yes, it is possible and for this, the users need to change the configuration in OPL8.

30) What is PRT in SAP PP?

It stands for Production Resource Tools. These are actually the movable operating objects that are of significant importance. They are considered when there is a need to repeat activities in the production.

Part 4:

Q1: How to configure the planning calendar for the ATP calculation where goods are shipped every other working day?

Ans: Use Transaction MD25 and define calculation rule for every other working day. Check the lot size settings in OMI4 and maintain relevant data in MMR.

Q2: We have two different production lines with different operations. One production line works 5 days a week and the other 7 days a week. The factory calendar is assigned to the plant for 5 days a week. This calendar is checked when MRP is run. How can we assign 5 day a week and 7 days a week against a factory calendar to the related resources?

Is it possible to have two types of calendars?

Ans: Assign factory calendars to the work centers.

Q3: What is the difference between by-product and co-product and how do you differentiate them in a BOM?

Ans: In case, of Co-product costs are settled with an apportionment structure. In case, of By-product the price of this by-product is credited to the order or the material stock account of the lead material being manufactured. Co-Product as well as by-product are defined as BOM Components/Items. Both of them have negative quantities. ( Not all negative quantity items fall under these categories!). When BOM is created for FERT, you can see one indicator in COMPONENT DETAILS screen for co-product. You need to define the co-products with this special indicator.

Q4: What are some important tables used in PP (Production Planning)?

Ans: For orders:

CUAFVD dialog structure for order headers and items
AFPO – Order item
AFFLD Order: Dialog table for order sequences (AFFL)
MOPER Operation for production order
KBED Capacity requirements
AFRU Order completion confirmations
RESB Reservation/Dependent Requirements
AFFHD Structure of PRT’s in orders
SOPER Sub-operations
SAFRU Sub-operation confirmations
SKBED Capacity requirements for sub-operation
MRP table is MDTB.

For PI:

CAUFV – AFVC Operation within an order
AFFT Order Process Instructions
AFFV Order process instruction values

Some other tables of interest:

PLKO, MAPL, PLAS.

Bills of Material

Q5: We have a BOM – ‘A’ with two packing materials ‘X’ and ‘Y’. For 1000 units of ‘A’, 1 packing material of ‘X’ is required and for 50 units of ‘A’, 1 packing material of ‘Y’ is required. Base quantity of ‘A’ is defined as 1000. How can I define ‘X’ & ‘Y’ or in fact ‘A’?

Ans: Make the base quantity of ‘A’ as 5000. The resulting component quantities would be 5 of ‘X’ and 100 of ‘Y’.

Work Centers

Q6: Can we have more than 6 standard values in standard value key?

Ans: One way to achieve this is to create another operation step using the same work center. However this shall be with a control key that is not a milestone. When the milestone operation is confirmed, the previous operations up to the next milestone are automatically confirmed. To get the desired number of standard values , all the ‘non milestone’ steps can be built depending on the need.

Routing

Q7: Can we use same routing for materials undergoing the same process/operations? Can we avoid separate routing for each and every material produced?

Ans: Presume that there are 50 products and the fabrication shop uses a set of 10 machines. If all these products use the same settings of the machines, Reference Operation Sets (task list type S) can be setup for common processes that use the same work centers. However costing, scheduling and capacity will be affected if each product has different setup time and Reference Operation sets can not be used.

A routing for each material number ( type N or R) has to be set up and within that routing, the Reference Operation Set can be used.However, you can by try utilizing the KMAT material and product variants invariant configuration to avoid separate routing for each material.

Q8: Scheduling times can be defined in the material master record by;

# entering the in-house production time. This value can be updated from the routing by the system.
# entering the setup, tear down, processing, and interoperation times. If these values are maintained, the system determines the in-house production time on the basis of lot size.

How do you get the system to update this value from the routing?

Ans: In routing, carry out scheduling. Go into the routing operation overview and follow Extras -> Scheduling -> Results. The pop-up window displays the scheduling data. At the bottom there is a pushbutton to copy the scheduling data to the material master Check this push button to update master data.

Q9: We have deleted a group key in an operation in routing and the same does not appear for this routing (CA02). But we noticed that entries are maintained in table PLPO and the deletion indicator is not set. How does the system remember this deletion of group key?

Ans: You may look at the tables PLKO, MAPL and PLAS.

Sales & Operations Planning

Q10: We defined SOP in months. However, during SOP transfer to demand management, our independent requirements are appearing in weeks. How can we correct this from weeks into months ?

Ans: Check transaction OMPA for general split. OMPS – based on the MRP group. Ensure that MRP group assigned to the material. Delete any allocations in these tables.
Then periods will be transferred to Demand Management with the same splits as in SOP. Also, check whether the value of period is set as “month” at your plant level in Transaction ‘OMP7’

Demand Management

Q11: Sales quantities in SOP for certain days are transferred into Demand Management and are shown as planned independent requirements. We need to keep the settings in SOP and change the periods in Demand Management? We would like to have a rolling horizon, for ex: the following 4 weeks on a daily basis, after that on a monthly basis. What is the best way to do this?

Ans: Use the automatic period split function.

M R P

Q12: We have a lot of size procedure here which is creating more order proposals. How do you set the limit value for the maximum number of MRP order proposals per date in IMG?

Ans: Under customization, try materials management->consumption based planning->maintain all plants

Q13: What is the difference between “planned consumption” and “Unplanned consumption”? Can safety stock calculation be done on either of these?

Ans: While customizing movement types (OMJJ) it is defined as to which set of consumption values gets posted during the material movement. For some, it may always be the total consumption and for some, it is always the unplanned one and for some, it is dependent on whether the issues were done with reference to a reservation ie., a planned consumption.

The way these consumption values are taken into account in MRP is defined in the customizing of MRP types.

For Reorder point planning (VM) the total consumption is used to calculate the safety stock and the reorder point.
For Forecast-based planning (VV) the total consumption is used to build the forecast which will be used to compile the order proposals.
For Deterministic MRP (PD) the unplanned consumption is used to calculate the forecast which in turn is added to the actual demand.

Q14: We want the system to run a single level MRP automatically on receipt of sales order. How to configure triggering event based MRP?

Ans: This can only be run if the material master has planning strategy 41 (made-to-order) in the MRP2 view. We need to run for other MRP types. We have to create a user exit in the sales order processing (VA01) to start MRP based on data from our sales transaction.

Q15: We have an assembly ‘A’ using a subassembly ‘B’. ‘B’ in turn uses raw material ‘C’. Item ‘A’ is an MPS and is duly marked in Material Master. Item ‘B’ and ‘C’ are marked as ‘PD’. When demand for ‘A’ is entered and MPS is run , upto which level the requirements are taken care of?

Ans: MRP can be run depending on your requirement. For example:

Single Item / Single Level from MPS – Transaction Code MD42 – Only the top MPS item ( ‘A’ in this case) is planned and dependent requirements will be passed to MRP item ( ‘B’ ) . Run MRP, Transaction MD02 on ‘B’ to plan it and all MRP items below.

Single Item / Multi Level from MPS – Transaction Code MD41 – All levels are planned – A, B & C

Total Planning from MPS online or background – Transaction Code MD40 or MDBS

Without marking the checkbox ” Process MRP materials” is like case ( 1) above and with the checkbox marked is like case (2 ).

Production Orders

Q16: We get an error message “Control parameters for scheduling not defined” while creating test production Orders. Why?

Ans: Before you attempt creating Production orders, configure your
Order types- Transaction Code OPHJ
Order type Dependent parameters – Transaction Code OPL8
Backorder Scheduling – Transaction Code OMIH
Scheduling Levels – Transaction Code OMIF

Q17: We are trying to create Purchase Requisition from MRP run. We have material, info Record, Source list, Demand in place. MRP is always creating plan order. Why?

Ans: Check the procurement type in MRP view of material master. Check ‘Create Purchase requisition’ indicator while running MRP. If you want purchase requisitions to be created in the opening period, select the for MRP control parameter ‘create purchase requisitions’ as ‘1’.

Q18: what is the option “Documented goods movements” on Selection of Individual Object Lists (transaction code CO28)?

Ans: Use Transaction code OPL8 to customize by choosing the order type, select all the checkbox under “Documentation of goods movements” at the bottom of the page. Create a new Production order, make GI to it, and run the report.

Q19: We would like to have a report/inquiry that would indicate variances (materials, material quantities) between material recipe and actual process orders. We tried ME2M but this gives us a list of purchasing documents and not the consumption deviation. Where can I get such consumption deviation (master recipe Vs. Process> Orders)?

Ans: Do a data collection first.

Menu Path – Accounting->Controlling->Product cost acctg->Process mfg->Information system->Cost object hierarchy->data collection

(If you are using order hierarchy you would select order hierarchy in place of cost object hierarchy in the menu path.)

Then, Accounting->Controlling->Product Cost Accounting->Order Related Production->Information System Choose Report Period Costing – Target/Actual production variance

Q20: We have two components ( ‘X’ & ‘Y’ ) in a production order in a process oriented production process. When 50 numbers of component ‘X’ are issued, we need the system to automatically issue 100 numbers of component ‘Y’ based on the ratio of 1 to 2. Where do I specify these ratios?

Ans: You can define the ratio in BOM and material may be issued with reference to BOM.

Q21: We have two storage locations are ‘0001’ and ‘0600’. Default storage location in Process order is always ‘0001’ What determines this default location?

Ans: Look into OSS notes: 100757, 63493, 96262, 87843, 82033, 64946. The Storage location as configured in the Supply area has the highest priority.

Q22: We need to do GI of components to production order using Back-flush. The component stock is managed in Batches. The Batch to be back-flushed

Ans: With the following settings, the batches are selected the moment the production order is released.

1: Set up batch determination the way that the batches in batch selection are sorted the right way. e.g. sorted by expiry date
2: Use automatic batch selection in disp view.
3: Ensure that the components are allowed to be back-flushed (material master/ work center) is selected by FIFO from the issue storage location. How can we set this up?

Q23: We want to report on several status combinations like each order that has status ‘Not deleted’ and ‘Not technically completed’. What set up is required?

Ans: Check transaction CO28. In the selection screen note the possible selection ‘System Status’. You can select TECO for technically complete an DLT for deleted from the list. Select the Excl. indicator also.

You may also try transaction CO26 (Logistics -> Production -> Production control -> Control -> Information systems -> Order Info System -> Object overview). Before executing the transaction report, combinations of statuses can be selected or exclude them.

Q24: How can we shut off the “automatic costing indicator” and the “automatic scheduling indicator” which go on when the production order is released?

Ans: For “no automatic costing” follow the IMG path
Production -> Production orders ->Master data -> Order – >Define order type dependent parameters
Select the order type for which u automatic costing is not required. In the controlling settings, select “no automatic costing”

For “no automatic scheduling”, follow the IMG path:

Production ->Operations – >Scheduling -> Define control parameters

Select the order type and go to details. Deselect ” automatic dates “

Alternatively, you can find indicators in the control key, which is in the routing. Transaction OPL8 gives you costing indicators (Order type dependent parameters), and OPJU (control table for scheduling) gives some scheduling options.

Variable Size

Q25: How can I use variable size items?

Ans: For example, consider an item A with ‘kg’ as base Unit Of Measurement(UOM) and ‘m3’ as stock keeping/issue unit. Conversion factor is 1kg = 2.4 m3.
In the BOM of ‘B’ ,number of A required are specified (say 5).

Specify the 3 variable dimensions i.e. length, width & thickness- say 2000mm X 3000mm X 4mm = 0.024 m3

As per BOM – ‘B’ , the quantity of A required is 0.024 X 5 = 0.120 m3

If a production Order is released for 15 numbers of ‘B’ , the quantity of variable size unit will be 1.20 m3.

You can change the length, width or thickness in the production order & check the resulting variable size item quantity. At the same time, this requirement can be seen in ‘kg’ in stock/requirement list.

Q26. Can MRP be carried out for one particular level of a bom ( Level code: 0001/0002 etc).

Ans: Yes it can be done by running for specific materials (Single Material Single Level)

Q27. How Requirements (PIR, Sales Order, Customer Requirement) are reduced after they are produced?

Ans: Reqmts are reduced automatically after Delivery is made to the Particular Order
(In case of Strategy 11, the PIRs are consumed after the GR for Production Order)

Q28. Can’t one material be assigned to more than one operation in a routing?

Ans: One material from a BOM CANNOT be assigned to different Operations. It can be done by defining the material for so many times as required in the BOM

Q29. How to insert an inspection checkpoint at the end of an operation?

Ans: If in process sample is to be defined, assign inspection type 03 in the Material Master.Then create MICs and assign them in the Routings. System automatically generates the Inspection Lots

Q30. Where have we to specify the teardown time in one operation?

Ans: Teardown time can be defined as one of the Standard Parameters…

Q31. How is the process time calculated in a WC when both labour, Machine categories exist?

Ans: Scheduling is done based on the Capacity Category we define in the Workcenter

Q32. How to create object dependencies in a BOM FOR A CONFIGURABLE MATERIAL?

Ans: Go to Extras -> Object Dependency -> Assign

For this, you need to create Characteristics and Class (of Class Type 300) earlier

Q33. Can anybody explain to me why work scheduling view is required for semi-finished and finished products? (Because we’ll mention all details in MRP views)

Ans: We need to maintain working scheduling view in order to make that finished or semi-finished goods available for production as we assign production scheduler and production scheduler profile in this view, if not maintained conversion of planned order to production will not be possible.

Part 5:

Q1. How many implementation project have you done? Explain your role?

Based on experience you can answer this question. Try to explain each project briefly and also mention your role in that project. If you don’t have any experience then you could show them your demo implementation, done during your training period.

Example:- I have 6+ year of experience in sap pp module as a functional consultant. I have done 2 full life cycle SAP-R/3 implementation and also I supported those projects. During Implementation I was involved in business requirement analysis, mapping clients’ business process to SAP processes (As Is-To Be), GAP analysis, Configuration, Re-engineering, Prototyping, Testing, Training, Documentation & Post-Go-Live Support.

Q2. What are the different type of manufacturing/production processes in SAP?

Manufacturing is the conversion (PROCESS) of certain INPUT into OUTPUT.
There are three types of manufacturing process handled in SAP.

Discrete manufacturing– Discrete manufacturing is the frequent switching from one manufactured product to another. The products are typically manufactured in individually defined lots and Costs are calculated on the basis of orders and individual lots.
Repetitive manufacturing– In Repetitive Manufacturing, products remain unchanged over a longer period and are not manufactured in individually defined lots.
Process Industries– Process manufacturing is a type of manufacturing that is associated with formulas and manufacturing recipes. Process manufacturing is common in the food, beverage, chemical, pharmaceutical, nutraceutical, consumer packaged goods, cannabis, and biotechnology industries.

Q3. Difference between discrete and repetitive production?

Discrete manufacturing	Repetitive manufacturing
It is Order based production /Lot based production	Period based production
Product changes frequently	The product remains unchanged over a period of time
Cost is calculated as per lot or prod order	Period based cost controlling.
GR movement type -101	GR movement type – 131

Q4. What do you mean by gaps in project implementation? Have you found any gap during implementation?

A gap during the project is referred to as “the space between where we are and where we want to be.” Gap analysis is undertaken as a means of bridging that space. GAP analysis is done in Blue Print stage. It aims to understand what can be done with the standard SAP and how the client actually wants a particular scenario to be processed. To Fill This Gap, We Use The Enhancements Like User exits, Field Exits, Screen Exits, Menu Exits, and etc.

You can give an example of any client specific requirement. It could be Report, interfaces, screen development, workflow, enhancements, class creation, function modules or in data migration areas.

Q5. What are the different documents we prepare in all phases during sap implementation?

Business Blue Print document, As-Is Document, TO-BE document, Gap Document, Configuration Document, Functional spec Technical Spec, Cut over document, Testing document, etc.

Q6. What are the steps of production execution process?

They are :

Converting planned order to production order
Releasing the production order
Goods Issue for the production order
Confirmation of production order
Goods Receipt against the production order

Q7. What are the basic difference between MTS and MTO?

Make to stock (MTS)	Make to order (MTO)
In MTS scenario company manufactures the product and keep it in stock, irrespective to any customer.	In this scenario, the product will be produced based on customer requirement.
Planning is done based on previous history or forecast.	Here sales order will trigger the production order.
Planning Strategies- 10 and 11	Planning Strategies- 20, 21, 25, 26

Q8. In SAP project the customization comes under which phase?

Realization.

Q9.What is the meaning of customized Reports?

When the standard reports provided by SAP does not meet the Business requirements, then we develop customized reports as per user requirements, often called Z reports. Developing reports can be done through ABAP custom reports / through Report Painter / ABAP Query.

Q10. What are the Master data in production planning?

Material master – Material master contains information related to different material types like the finished product, raw material. A material master can be used for identifying a product, purchase material, goods issue or good receipt, MRP, and production confirmation.

BOM – A formally structured list of the components that make up a product or assembly. The list contains the object number of each component, together with the quantity and unit of measure.

Routing – Routing defines the sequence of activities performed at the work center. Routing plays an important role in calculating production cost, machine time, and labor time.

Work center – Work center consists of master data related to the routing of products. It contains data related to scheduling, capacity planning, and product costing.

Q11. Describe different types of scrap. Where all different types of scrap can be maintained on SAP user screens?

There are three types of scraps used in SAP PP:

Assembly Scrap
Component Scrap
Operation Scrap

Assembly Scrap – During the production of an assembly, a certain amount of scrap always occurs due to various reasons. To produce the required lot size it is always necessary to increase Quantities and activities used by the system.

Settings – You have to maintain the assembly scrap in the material master (MRP1 view) as a percentage in the Assembly scrap field

Component Scrap – Some times a particular component always consumed more during a production process than the planned one. In that case, we use component scrap quantity to achieve the production quantity. Component scrap increases the dependent requirements quantity of the component.
You can maintain component scrap:

In the BOM item – In this case, the component scrap is only relevant for this particular BOM.
In the MRP 4 view of the material master record – In this case, the component scrap is relevant for all the BOMs that contain this material.

Operation Scrap – During Production process after a particular operation, you may get some loss. Now you need to adjust the qty, standard values and other values of the subsequent operations. For this Operation, scrap is used in production.

Settings – You can enter operation scrap (in %) in the routing and in the BOM.

Q12. What is the difference between by-product and co-product and how do you differentiate them in a BOM?

Co-Product – A co-product is a product that is produced in conjunction with other products. The system creates a separate order item in the production order for each co-product.

By Product – It is an output from a production process which can be useful/sellable or sometimes can be waste. The System Does not create a separate order item for each by-Product

BOM Settings- negative sign is used for co-products and also co-product indicator should be active in BOM. And the byproduct has only the -ve quantity in BOM component.

Q13. Difference between BOM group and group BOM?

BOM Group – It is a collection of bills of material that lets you describe a
product or a number of similar products.

Group BOM – It is a BOM wherein u do not assign any plant while its creation. This means this BOM can be later assigned to any plants as per requirement.

Q14. What is super BOM?

The BOM which we maintain for Configurable materials is called as Super BOM. It contains all the possible components that are required to manufacture the material.

The BOM contains components that are only used in specific variants (variant parts), as well as components that are used in all variants (non-variable parts). This is why BOMs for configurable materials are known as super BOMs.

You can use the dependency to select the exact component based on the conditions given in the dependency.

Q15. What do you mean by variant BOM?

Several similar materials which have common parts can be created as SAP variant BOM. SAP variant BOM will have BOM technical type “V”. BOM group for all these variant bills of materials will be the same. This helps business users to simplify BOM maintenance.

Q16. What is the use of t-code CS20 in BOM?

CS20 t-code (mass change BOM) used to change items in several BOMs at once.
In this transaction code, you can –

Mass change BOM item data
Mass delete items
Mass create materials etc.

Q17. How many maximum no. of alternative BOM can be created?

Q18. How you can attach drawing to BOM?

One can attach a document to a BOM in one of the following three ways:
1) Attach document as an item in the item overview,
2) Attach the document to an item and
3) Attach the document to the header material.

Create Document with using T-code CV01N and attach your drawing to this document. Now, in BOM select Item category D and insert your document number.

Q19. Why their is need of production version ?

A production version determines which alternative BOM is used together with which task list/master recipe to produce a material or create a master production schedule. In a production version, you can maintain the combination of BOM and routing. You can use the production versions based on:
1. Lot size qty.
2. BOM explosion dates
3. Based on MRP Group

Q20. What is the Difference between TECO and CLSD?

TECO means Technically complete. By setting status TECO; the order from the logistics point of view is set as complete. However, You can carry out Variances, settlements on the order.

CLSD – Once the order is TECO and all the settlements are completed then the order will be set to Close. Until unless all the settlements are done on the order; the order cannot be closed

Q21. What is a phantom assembly ?

Phantom assemblies are assemblies that have their own product structure, but whose assembly does not physically exist. The components of the phantom assembly are incorporated directly in the superordinate product. The product structure of the superordinate product contains a reference to the phantom assembly. In simple words SAP, a phantom assembly is a special non-stock material that has its own components.

Q22. What are the Costing Parameters in SAP PP?

Work Center: Activity types and the formulas, cost center
Routing: The time, activity types

Q23. What is Backflush and the places where the backflush is used?

In simple word, Backflushing is automatic goods issue. The system will automatically post the goods issue when you confirm the operations. You have no need to make the manual issue. Basically, backflush is used where it is having a fixed relationship.

In SAP, backflushing can be carried out in 4 ways:

Material Master-MRP 2 View
Work Centre- Basic data
Routing-component assignment
Production Order- Component overview

Out of the above 4 options, the material master takes the highest priority if the backflush indicator is set at multiple places.

Q24. What is the movement type for Goods issue reversal?

Movement type is 262 for Goods issue reversal.

Q25. What is MRP profile?

SAP MRP profile is defined as a key that contains a set of MRP view field values to be maintained during material master creation. It helps to minimize the repetitive task of maintaining the MRP fields. This profile has two types of values – fixed values and default values.

Create – MMD1
Change – MMD2
Delete – MMD6

Q26. Difference between MRP and MPS?

Material requirement planning (MRP) is a set of techniques that uses the bill of material data, inventory data, and the master production schedule to calculate requirements for materials.

Master production scheduling (MPS) is a form of MRP that concentrates planning on the parts or products that have a great influence on company profits or which dominate the entire production process by taking critical resources. These items are marked as ‘A’ parts (MPS items) and are planned with extra attention. In simple words, MPS helps you plan the manufacturing process of Independent Demand Items.

Q27. What is MRP controller?

The MRP Controller in SAP, Material Requirements Planning Controller, is a mandatory field in Material Master.

It represents the person, or group, that will be responsible for controlling the workflow scheduling.

Q28. What is planned cost, Actual cost and target cost

Planned cost = Planned qty X Planned cost
Actual cost = Actual qty X Actual cost
Target cost = Actual qty X Planned cost

Q29. What are the different standard MRP types in SAP PP?

PD – Normal MRP
ND – No planning
VB – For manual reorder point
VM – Automatic reorder point
MPS – For A category material

Q30. What are the key fields in MRP1 View?

General Data
MRP Procedure
Lot Size data

Q31. What are the key fields in MRP3 View?

Forecast Requirement
Planning
Availability Check

Q32. Difference between Customer Independent requirement (CIR) and Planned Independent requirement (PIR)?

PIR: Planned Independent Requirements are planned production or sales quantities that are based on some sort of forecast procedure (e.g. Material Forecast or SOP procedure). These values are used in MRP to calculate procurement and production quantities for a material. As the name suggests, PIR is not dependent on any requirement. We use T-code MD61 for maintaining the quantity based on the forecast (Past history and future trend). It is mainly used in MTS scenario

CIR: In Customer independent requirement the customer details are not required, only details like date and requirement type are required and when planned order gets created has assigned to the CIR and the material you receive to Stock goes to special stock E. it is created by using T-code MD81 and It is mainly used in MTO scenario. The customer requirements that you create in MD81 have the same requirement as the customer order created in VA01. This option is mainly used to simulate or when you don’t have the SD module.

Q33. Difference between NETCH, NETPL & NEUPL?

NETCH – Net change for a total horizon
Those materials will be planned which have undergone a change relevant for MRP since the last planning run like a change in stock, material master or creation of new receipt, etc.

NETPL – Net change for a planning horizon
All requirements will be planned which falls under the planning horizon from the day of the MRP run irrespective of changes were done or not.

NEUPL – Regenerative planning
MRP is run for all the materials if they have a change in planning or not. AS the name suggests this is regenerative. System plans for all the materials in the planning file.

Q34. What is Schedule Margin key?

Schedule margin key is used to define the production order floats to determine the production dates in Production Order /Planned Order.

Opening period – The opening period represents the number of workdays that are subtracted from the order start date in order to determine the order creation date.

Float before production– It represents the number of workdays that are planned as a float between the start date (planned start date) and the production start date (target start date).

Float after production – The float after production should provide a float for the production process to cope with any disruptions so that there is no danger that the planned finish date will be exceeded.

Release period – The release period represents the number of workdays that are subtracted from the order start date in order to determine the production order release.

Q35. What is availability check?

The availability check in Shop Floor Control checks whether the components, production resources/tool or capacities required for a production order are available.

Q36. What is planning fence time?

The planning time fence specifies a period within which no automatic changes are to be made to the master plan. It is maintained in workdays.

Q37. What is difference between MD04 and MD05 t-codes?

MD04 (stock requirements list) – Dynamic in nature ie. It shows the current situation for stock. In other words, the stock requirements list shows the most up-to-date stock and requirements situation. stock requirements lists are not saved in a fixed state in the system, but are subject to change and only exist in the working memory.

MD05 ( MRP list) – Static in nature, The MRP list always displays the stock/requirements situation at the time of the last planning run and it also provides a work basis for the MRP controller. Changes that are made after the planning date are not taken into consideration. MRP lists are stored in the system until they are either deleted manually or replaced by new lists from a subsequent planning run.

Q38. What are different Planning strategies?

Make-to-Stock Production (10/11 ) – As the name implies, Make-to-Stock Production is a strategy that utilizes forecasts as the basis to drive production of end items and components. It is particularly useful for mass production environments. Make-to-Stock Production is defined in SAP as two different Planning Strategies, 10 and 11. They differ in the way they treat Available Stock. Planning Strategy 10 will consider Stock (net requirements planning) while Planning Strategy 11 will not (gross requirements planning).

Make-to-Order Production (20/ 21/ 25/ 26) – As the name implies, Make-to-Order Production is strategies that utilize Sales Orders as the basis to drive production of end items and components. These strategies are useful when production orders need to be directly linked to sales orders. The differences between the several MTO strategies are combinations of how costs are settled (in all cases to Sales Orders versus stock) and the degree with which configuration of the Sales Order (for a configurable material) is required. Strategies 20 and 21 do not allow configuration, 25 requires it, and 26 makes it optional.

Production by Lot Size for Sales and Stock Orders (30)– This strategy is particularly useful for companies that mainly produce for major customers but who also require the option of selling smaller requirements from stock. Several sales orders, depending on the dates, can be grouped together to be produced in one single lot. In addition to the recognition of Sales Orders, this strategy will also plan to cover Planned Independent Requirements like the Make-to-Stock Strategy.

Q39. What is COGI report/error?

COGI stands for Controlling Goods Issued and is a standard SAP transaction which shows a report of automatic goods movement errors. Automatic Goods Issues are carried out by the production confirmation if the Backflush indicator is set on the MRP1 View.
Common COGI Errors are:

Storage location field empty
Material does not exist
Deficit of SL Unrestricted-use of material

Q40. What are all the steps involved in Variant Configuration?

Variant Configuration is a special feature of SAP which helps to simplify the complex manufacturing of a final product with more varieties and variation of the input material.

Create a material (MM01) – KMAT type with Item category (002)
Create a Characteristic (CT04)
Create a class (CL01) and assign characteristics to class – In the variant configuration class type (300) is used.
Attach the above class to KMAT Material.
Create a Configuration Profile (CU41) – It contains control data for the configuration process and result.
Create a super BOM (CS01) – Contains all the component required to manufacture all variants of the product.
Create a super routing (CA01) – Contains all the operations for producing all variants of the product.
Create dependency (CU01) – Create dependency for all the material of BOM.
Assign the dependency to material in BOM.
Assign the same object dependency to the super routing operations.
Scenario testing (CU50) – Check whether the system is selecting appropriate BOM material and operations for given characteristic values.
Maintain pricing and condition record for each variant – use T-code VK11. Create a sales order for variant material and select its characteristic value assignment in the sales order.
Run MRP for the sales order, you will get planned order. Convert it to production order.

Q41. Dependency types in variant configuration?

Dependencies let you Control which components are selected from a bill of material (BOM) and which operations are selected from a task list

The SAP system supports the following types of dependencies:

Preconditions – to hide characteristics and its values
Selection conditions – to select characteristics or values
Actions – to infer a value for characteristics but obsolete.
Procedures – to Infer value for a characteristics
Constraints – It provides value assignment and consistency check in a single level and multi-level configuration. Additional reporting options for equations, variant tables, and variant functions.

Q42. Integration between sap PP and SD modules?

Integration between PP and SD happens in the following scenarios –

A) Demand Management: Make to order manufacturing
B) Variant Configuration: Based on the characteristic values assigned in the sales order, picking of the components from Super BOM and picking of the operations from Super routing
C) During availability check

Q43. Integration between PP and MM Module?

Integration between PP and SD happens in the following scenarios:

Bill of Materials (BOM) – Once we define the BOM for the Header material (such as the finished good), we can get the exact requirement for the quantity of inventory.

Material Requirement Planning for External Procurement (MRP) – Once we maintain the MRP views in Material Master, we can generate the automatic reservation and Purchase Requisition after running the MRP.

Stocks Determination – when we issue and receive material to production order.

Q44. Integration between PP and QM Module?

Integration between PP and SD happens in the following scenarios:

In process inspection during Production – This is used when you required to check the product at regular intervals. Need to activate Inspection type 03 in material master Quality management view.

Inspection after Goods Receipt for Production order – This is used when it’s required to check the product after completion of the production process. select Inspection Type 04 in the quality management view in the material master.

Q45. What are the important tables in SAP PP?

Material Master

MARA – General material data info
MARC – Plant level data (purchasing, safety stock etc)
MARD – storage location data
MAST – Material to bill of material linkage
MARM – Unit of measure of material data
MAKT – Material description table
MBEW – Material valuation info (price related data)
MAPL- Assignment of task list to material (routing)

BOM

STKO – BOM header
STPO – BOM item

Work Center

CRHD – Work center header
CRHH – Work center hierarchy
CRCA – Work center capacity allocation
CRCO – Assignment of work center to cost center
KAKO- Capacity header segment data
KAKT – capacity description
KAPE- the Capacity unit of measurement.

Routing

PLKO—Task list header info
PLPO – Task list operation info
PLFL – Task list sequence info
PLMZ – Allocation of BOM to the operation

Production version

MKAL – Production version of a material

MRP

MDKP – Document header data
MDTB – Table structure
MDFD – MRP date details

Production Order

AFKO – Order header data
AFPO – Order Item

Order Confirmation

AFRU – Order confirmation
AFFW – Order Confirmations – Goods Movements with Errors

SAP PP Interview Question and Answer

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