Streamline your production planning process with SAP S/4HANA! Get step-by-step instructions for configuring and using SAP S/4HANA for discrete, process, and repetitive manufacturing. Then dive into production tools and functionalities like batch management, S&OP, predictive MRP, DDMRP, and the Early Warning System. This foundational guide is full of industry examples to help you maximize your production planning!Highlights include:1) Discrete, process, and repetitive manufacturing2) Batch management3) Sales and operations planning (S&OP)4) Demand management5) Demand-driven replenishment (DDR)6) Material requirements planning (MRP) 7) Predictive MRP8) Long-term planning 9) Capacity requirements planning10) Early Warning System11) Reporting and analysis

((Second edition, updated and revised))

... Acknowledgments ... 29... Preface ... 31... Goals of This Book ... 32... Target Audience ... 32... Structure and Content ... 33PART I ... Core Production Planning Concepts ... 371 ... Introduction to Production Planning with SAP S/4HANA ... 391.1 ... Production Planning and Control ... 401.2 ... Comparison Table of Production Types ... 521.3 ... Production Planning Features in SAP ERP and SAP S/4HANA: A Comparison ... 561.4 ... SAP Integrated Business Planning for Supply Chain ... 581.5 ... Summary ... 602 ... Organizational Structure in SAP ... 612.1 ... Breaking Down the Structure into Units ... 612.2 ... SAP Calendar ... 692.3 ... Summary ... 73PART II ... Production Planning Configuration ... 753 ... Discrete Manufacturing Configuration ... 773.1 ... Material Master ... 783.2 ... Bill of Materials ... 793.3 ... Work Center ... 843.4 ... Routing ... 943.5 ... Production Order Configuration ... 963.6 ... Order Type-Dependent Plant Parameters ... 1003.7 ... Production Scheduling Profile ... 1043.8 ... Default Values for the Generation of Operations ... 1073.9 ... Availability Check ... 1083.10 ... Scheduling ... 1133.11 ... Reduction Strategy ... 1173.12 ... Confirmation ... 1183.13 ... Reason for Variances ... 1263.14 ... Trigger Points ... 1273.15 ... Define Print Control ... 1273.16 ... Background Jobs ... 1283.17 ... Summary ... 1294 ... Process Manufacturing Configuration ... 1314.1 ... Master Data in Process Industries ... 1324.2 ... Order Type-Dependent Parameters ... 1354.3 ... Production Scheduling Profile ... 1384.4 ... Process Management ... 1404.5 ... Process Messages ... 1444.6 ... Process Instruction Category ... 1494.7 ... Control Recipe/Process Instruction Sheets ... 1644.8 ... Background Jobs ... 1684.9 ... Process Manufacturing Cockpit ... 1694.10 ... Summary ... 1725 ... Repetitive Manufacturing Configuration ... 1735.1 ... Repetitive Manufacturing Profile ... 1745.2 ... Scheduling Planned Orders ... 1855.3 ... Display ... 1865.4 ... Material Staging ... 1885.5 ... Global Settings for Confirmation and the Logistics Information System ... 1895.6 ... Operational Methods Sheet ... 1905.7 ... Summary ... 191PART III ... Production Planning Workflows ... 1936 ... Production Planning for Discrete Manufacturing ... 1956.1 ... Process Overview ... 1966.2 ... Master Data ... 1976.3 ... Production Order Management ... 2326.4 ... Release Production Order ... 2506.5 ... Printing ... 2526.6 ... Material Withdrawal ... 2556.7 ... Confirmation ... 2616.8 ... Goods Receipt ... 2676.9 ... Postprocessing ... 2706.10 ... Settlement and Completion ... 2726.11 ... Additional Functions and Information Systems ... 2746.12 ... Summary ... 2787 ... Production Planning for Process Manufacturing ... 2797.1 ... Process Manufacturing Overview ... 2807.2 ... Master Data in Process Manufacturing ... 2817.3 ... Characteristics ... 2907.4 ... Process Management ... 2947.5 ... Process Order Execution ... 3077.6 ... Process Management in Action ... 3087.7 ... Execution Steps ... 3187.8 ... Process Messages Evaluation ... 3297.9 ... Process Manufacturing Cockpit ... 3307.10 ... Resources Network ... 3317.11 ... Summary ... 3368 ... Production Planning for Repetitive Manufacturing ... 3378.1 ... Overview ... 3388.2 ... Master Data ... 3418.3 ... Material Requirements Planning in Repetitive Manufacturing ... 3598.4 ... Planning Table ... 3628.5 ... Material Staging ... 3728.6 ... Production List ... 3758.7 ... Confirmation ... 3778.8 ... Reversals and Scrap ... 3868.9 ... Costing Activities (Cost Object Controlling) ... 3918.10 ... Heijunka ... 3928.11 ... Reporting ... 3938.12 ... Summary ... 395PART IV ... Production Planning Tools ... 3979 ... Kanban ... 3999.1 ... Kanban Overview ... 4009.2 ... Push-Pull Principle ... 4029.3 ... Kanban Replenishment Strategies ... 4049.4 ... Configuring Kanban ... 4069.5 ... Setting Up Kanban Master Data ... 4199.6 ... Replenishment with Kanban ... 4239.7 ... Evaluating and Reporting Kanban ... 4509.8 ... Summary ... 45510 ... Batch Management ... 45710.1 ... Batch Management Overview ... 45710.2 ... Batch Level and Batch Status Management ... 45910.3 ... Master Data in Batch Management ... 46310.4 ... Business Processes of Batch Management ... 46710.5 ... Batch Determination ... 47410.6 ... Recurring Inspection and Expiration Dates ... 48610.7 ... Batch Derivation ... 49310.8 ... Batch Traceability of Work in Process Batches ... 50310.9 ... Batch Information Cockpit ... 51210.10 ... Electronic Batch Record ... 51510.11 ... Summary ... 51711 ... Sales and Operations Planning ... 51911.1 ... Standard Sales and Operations Planning ... 52011.2 ... Flexible Planning ... 53811.3 ... Version Management ... 55911.4 ... Forecasting ... 56111.5 ... Rough-Cut Planning Profile ... 57411.6 ... Events ... 57811.7 ... Mass Processing in Sales and Operations Planning ... 58411.8 ... Standard Analysis in Flexible Planning ... 58611.9 ... Summary ... 58912 ... Demand Management ... 59112.1 ... Elements of Demand Management ... 59212.2 ... Strategies for Make-to-Stock Production ... 59812.3 ... Strategies for Make-to-Order Production ... 60912.4 ... Strategies for Assemble-to-Order ... 61512.5 ... Strategies for Planning Components ... 62012.6 ... Production with Variant Configuration ... 62312.7 ... Create a Custom Requirement Class ... 62612.8 ... Business Processes in Demand Management ... 63012.9 ... Summary ... 64213 ... Foundations of Material Requirements Planning ... 64313.1 ... Process Overview ... 64413.2 ... Deterministic Replenishment Procedures ... 65113.3 ... Stochastic Replenishment Procedures ... 66313.4 ... Configuring Material Requirements Planning Types ... 66813.5 ... Lot Sizing Procedures ... 67113.6 ... Rounding ... 67913.7 ... Scrap ... 68113.8 ... Safety Stock ... 68413.9 ... Scheduling ... 69013.10 ... Procurement Proposals ... 69513.11 ... Configuration Settings for Material Requirements Planning ... 70213.12 ... Summary ... 70514 ... Running Material Requirements Planning ... 70714.1 ... MRP Live ... 70914.2 ... Stock/Requirements List ... 71314.3 ... Planning Calendar ... 72814.4 ... Planning Areas ... 73014.5 ... Classic Material Requirements Planning ... 73514.6 ... Types of Planning Runs ... 73714.7 ... Summary ... 73915 ... Demand-Driven Replenishment ... 74115.1 ... Limitations of Current Materials Planning and Replenishment Tools ... 74215.2 ... Material and Information Flows ... 74415.3 ... DDMRP Basics and Components ... 74615.4 ... DDMRP Setup ... 75715.5 ... Running Demand-Driven Replenishment ... 76815.6 ... Summary ... 80516 ... Long-Term Planning ... 80716.1 ... Long-Term Planning Master Data and Planning Data ... 80816.2 ... Long-Term Planning: Business Process ... 81516.3 ... Additional Features in Long-Term Planning ... 82016.4 ... Evaluate Information Systems ... 82616.5 ... Summary ... 83217 ... Predictive Material and Resource Planning ... 83317.1 ... pMRP Basics ... 83417.2 ... pMRP Setup ... 83517.3 ... Managing pMRP ... 83917.4 ... Releasing pMRP Results to Operative MRP ... 84717.5 ... Summary ... 84818 ... Capacity Requirements Planning ... 85118.1 ... Process Overview ... 85218.2 ... Capacity Requirements and Capacity Evaluation ... 85418.3 ... Finite Scheduling ... 86918.4 ... Dispatching ... 87018.5 ... Capacity Planning Table ... 88518.6 ... Summary ... 89119 ... Production Planning and Detailed Scheduling ... 89319.1 ... Configuration ... 89519.2 ... Master Data in PP-DS ... 90019.3 ... Business Processes ... 91719.4 ... Heuristics ... 92419.5 ... Production Planning Run ... 92619.6 ... Reporting and Monitoring Apps ... 93919.7 ... Alert Monitor ... 94519.8 ... Plan Monitor ... 94619.9 ... Summary ... 95120 ... Production Engineering and Operations ... 95320.1 ... Key Terminologies ... 95520.2 ... Configuration Settings and Production Engineering and Operations Setup ... 95620.3 ... Production Engineering Master Data Setup ... 96420.4 ... Planning in Production Engineering ... 97920.5 ... Production Operations ... 98320.6 ... Reporting ... 99720.7 ... Summary ... 999PART V ... Monitoring and Evaluating Production Planning ... 100121 ... Early Warning System ... 100321.1 ... Overview ... 100321.2 ... Exceptions ... 100521.3 ... Set Up Periodic Analysis ... 101121.4 ... Schedule an Early Warning System ... 101421.5 ... Triggering an Early Warning System ... 101521.6 ... Exception Analysis ... 101721.7 ... Summary ... 102022 ... Production Planning Reporting ... 102122.1 ... The Basics of Reporting ... 102122.2 ... Report Parameters ... 102222.3 ... Order Information System Reports ... 103222.4 ... Missing Parts Information System ... 103522.5 ... Summary ... 103623 ... Standard Planning Analysis ... 103723.1 ... Discrete Manufacturing/Production Order ... 103723.2 ... Process Manufacturing/Process Order ... 104323.3 ... Repetitive Manufacturing ... 104323.4 ... Additional Analysis Functions ... 104323.5 ... Summary ... 104724 ... SAP Fiori Apps for Production Planning ... 104924.1 ... SAP Fiori Launchpad and Apps Library ... 104924.2 ... SAP Fiori Applications ... 105024.3 ... Summary ... 1072... The Author ... 1073... Index ... 1075