PP Scenario Mapping help Needed

Question

Hi Guys
Can anyone please help to map the following scenario?
<b>Scenario:</b> SAP PP
<b>Product:</b> Ingot
<b>Size:</b> Ingot 100 X 100, Ingot 125 X 125, Ingot 160 X160
<b>Grade:</b> A, B, C,……
<b>Saleable Item:</b> Ingot100 X100 Grade A, Ingot100 X100 Grade B, Ingot160 X160 Grade C etc. (i.e. combination of Grade & Size will determine the saleable items.)
<b>Characteristics to determine Grades:</b> Carbon%, Phos%, Mn%,………
<b>Requirement:</b>
1.     Planning scenario make to Stock and stock will be maintained size and grade basis(e.g. Ingot100 X100 Grade A = 110 TO, Ingot 100X100 Grade B = 124 TO etc.).
2.     Planning will be done at Ingot level.
3.     Batch no will be used to track the heat number during GR of Billet.
4.     There will be a BOM & Routing to produce Billet.
5.     Size and grade will be determined during quality Inspection i.e. as per MIC (Carbon%, Phos%, Mn%,………etc) value.
<b>SAP requirement:</b>
1.     Planning Strategy for Ingot.
2.     In which Stage production confirmation will be carried out.
3.     Process mapping for saleable items.(Whether it’s necessary to open individual material code for each saleable items. If yes what will be the planning strategy for saleable items. But if no what will be the mapping)
4.     Costing basis (at Ingot level or at saleable item level? If at saleable item level then what will be the cost components in between Ingot and saleable item level)
Looking forward for any valuable suggestion.
With Best Regards
Soumya Das
SAP PP-PS Consultant
Kolkata
Hello: [phone]

Answer 1

Basically I am FI/CO consultant and worked on CO implementation project. So based on my costing view ,I can give you some  rough Idea.
1) As your planning is make to stock  , but still  does your production planning flows from your sales planning or not. In SAP you can  create your production planning either directly or from your sales planning.
2) You can Plan your material down the bill of material also i.e
at the raw material level level also. Technically each of your finished product might have standard BOM quantity and standard tak time (cycle time ) for each process which is defined in routing.So when BOM is exploded at the time of demand creation ,it explodes both your bill of material as well as your routing.Inshort if your FG  is made up of  X quantity of A and Y quanitity of B plus it goes machining activity of 5 minutes for each quantity produced . So If my production planning is of 1000 unit . Then after explosion it will plan
1000X of A and 1000Y of B plus 5000 minutes machine time will ple planned.And based on production lead time,procurement lead time and available stock,and available capacity for production,it will schedule the production.
3) Confirmation will be done again based on the requirement.If you want calculate WIP stock at each stage .Then it has to be confirmed at each stage to know the WIP stages. Plus at what process you do the quality inspection.In that case you have to confirm the process and then make the qc and then you have to start the new operation.
4) Yes you have to open the seperate material code for the saleable material as well as semifinished material.Your SFG will also contain the BOM and routing
5) Costing will be basically your raw material cost(which will come from bom),material overhead(come from costing sheet), Process cost(come from routing),manufacturing obverhead(come from costing sheet),administrative overhead(come from costing sheet) and sales and distribution overhead(come from costing sheet) depending on the costing requirement.
Regards
Sameer Kumar