Dipayan SahaRelated papers
Implementation of System Application Product (SAP) Materials Management (MM-Module) for Material requirement planning (MRP) in Sugar Industry
ijsrp.org
SAP has been delivering on its Sugar industry strategy by expanding its capabilities for manufacturing and supply chain management, broadening its composite package applications in areas such as emissions management, pricing management, and manufacturing dashboards, and focusing on mid-market companies. To implement an integrated system of production planning and materials management, there must have a central database wherein anyone in the company can find out all there is to know about any material passing through the plant. Everyone must use the same rules and data structures when they enter data about material details. The integration of all material data in a single database object eliminates redundant data storage. Areas such as purchasing, inventory management, material requirements planning (MRP), invoice verification, and so on, can all use the same data. By implementing SAP (MM-Module) in sugar industry for Material requirement planning, the product can be ordered and received within safety period. Based on material group classified under ABC analysis. Planning can also be done on priority by calling vendors for particular commodities through online.
The SAP Materials Management Handbook
Cross-plant CM. If the material is configurable and available at more than one plant, select the cross-plant change management configuration of the material. Material is configurable. Check this box if the material is configurable.
Benefits of Centralized Materials Management: A Case Study in the Direct Selling Industry
2013
Bulk: The contents of the packaging, e.g. the perfume inside the bottle. Component: That what is used to contain and package the bulk of the product. Materials: In this study the word materials always refers to the raw materials and components that are converted into finished goods. Material flow: In this study material flow is only used in the narrow sense to refer to the flow of raw materials and components into the factories. The outward flow is generally not referred to. Materials management: In this study the term materials management is taken to mean the planning and purchasing of materials. Minimum Order Quantity (MOQ): In this study MOQ only refers to the minimum order quantity requirement set by the supplier of goods (either materials or finished goods). However, in Oriflame this term is used also to refer to the varying order quantities associated with different price breaks. Multi-product materials: Is used in this study to refer to materials that are used in more than one product. Multi-sourced product: In this study is used to refer to a product code that is produced in more than one factory. Pricing: Is used to refer to high-level price negotiations of raw material and components on an aggregated annual volume. It is also used in the broader sense to refer to establishing the framework agreement with materials suppliers. Purchasing: Is used to refer to the actual act of ordering materials, it includes deciding to act on or change the planned material flow into the factory. Planning: Is used to refer to the planning of material flow into the factory, it includes planning what, when and how much to order. Product code: Each unique product has a product code, and thus the term product code is used to refer to a unique product. Finished goods: The final product that remains after raw materials and components have passed through conversion processes. Factory: The term factory is used to describe finished goods suppliers. They convert raw materials and components into finished goods, through mixing, filling and packaging processes. Therefore the terms filler, finished good supplier and factory is used interchangeably. In some instances the word site is also used to refer to the factory. vii R: Statistical computing software. Raw materials: Is the basic materials used in producing the bulk of the products. Supplier: The term supplier refers to the raw materials and components suppliers. When referring to finished goods suppliers, it is explicitly stated or clear from the context. Supply schedule: The schedule that indicates the weeks in which finished goods should be delivered.
Bill of Material (Bom) Pada Sistem Inventori Kawasan Berikat Untuk Pelacakan Material Movement
ILKOM Jurnal Ilmiah, 2018
Suatu perusahaan manufacturing mengolah bahan mentah (raw material) menjadi barang setengah jadi (work in process) dan barang jadi (finish good). Salah satu perusahaan manufaktur injection molding di Karawang memproduksi bahan plastik untuk dicetak menjadi berbagai macam bentuk perlengkapan keamanan kendaraan.Tiga proses utama yang terjadi dari bahan mentah sampai barang jadi adalah penyimpanan raw material di warehouse, proses perubahan raw material menjadi finish goods di area produksi, dan penyimpanan finish goods untuk dikirim ke customer. Bill of Material (BOM) dirancang untuk memuat semua perubahan bentuk sehingga mempermudah dalam penghitungan kebutuhan raw material dan pelacakan pergerakan material (material movement). Sistem informasi ini dirancang menggunakan metode Extreme Programming (XP). Hasil penelitian ini membantu pengelolaan barang produksi di Perusahaan Manufactur Injection Molding dari mulai raw material, work in process, sampai menjadi finish good yang diperlukan perusahaan untuk pelacakan data barang serta untuk memenuhi kepentingan pelaporan secara real time yang diminta oleh Bea Cukai.
Materials Management and Its Effects on Cost of Supplies : Materials Management
2008
First and foremost, the authors' will like to express their thanks to our supervisor Sigvard Herber for his support and guidelines throughout this research work. Our other thanks go to all friends and loved ones, who helped to make this work possible. Finally, the authors' will like to thank the respondents and the management of Cocoa processing Company of Ghana for their support.
ANALISIS PENERAPAN MFCA (MATERIAL FLOW COST ACCOUNTING) PADA INDUSTRI MANUFAKTUR (Studi Kasus Pada PT. Unipres Indonesia)
Jurnal Apresiasi Ekonomi
This research analyzes the implementation of material flow cost accounting (MFCA) in the manufacturing industry with an analysis unit at PT. Unipres Indonesia. This research aims to determine how the implementation of material flow cost accounting (MFCA) in the manufacturing industry focused on PT. Unipres Indonesia. The implementation of MFCA is reviewed based on the (Clause 5, ISO 14051:2011) which consists of quantity center, material balance, cost calculation and material flow model. This research is a qualitative research with a case study approach. The source of data consists of interviews and documentation. This research used Miles and Huberman data analysis while triangulation and member checking use as reliability and validity data. The result of this research can be conclude that the implementation of MFCA at PT. Unipres Indonesia has been done optimally based on the four aspects measured. quantity center, material balance, cost allocation and material flow model. MFCA application results showed that the company has the cost of material loss of energy costs, system costs and material cost of Rp 650.325 for one product parts produced.
Enterprise Resource Planning of Procurement Process with SAP MM Module
International Journal of Innovation in Enterprise System
PT XYZ is one of the mining companies in Indonesia that has many subsidiaries. From user interviews, there’s a problem in carrying out daily transactions in the procurement process. There is no integration between departments when using existing applications, lots of inappropriate data, and some documents with missing files. Thus causing data not on time and working time. The analysis was carried out using a conceptual model to see the problems and needs in PT XYZ. ERP system needs to be implemented, coordinating the company’s business processes and reset the company’s infrastructure and standardization. The ERP system in the material management module will be implemented using the ASAP method because this method is tailored to the company. The ASAP method can describe implementation activities to support project management and data migration faster than other implementation methods.
Material Planning and Management System in GPH Ispat Ltd
This report is based on the material management and resource planning process of industrial unit and the outcome will recommend the industries about effective management of resources identifying the loopholes that lengthening the process to accelerate efficiency. None of the text of the dissertation is taken directly from previously published or collaborative articles. Chapter one is containing the introductory part, rationale, objectives, methodology and some limitations of the study. History of the company, nature of its business, products, distribution process, company’s mission, vision and its core objectives have been illustrated in Chapter two. Chapter three has detailed information about material procurement, inventory management process, logistics invoice verification, planning for materials, documents processing, scheduled raw material scheme, trend analysis of the production level, available stocks maintenance and some flaws regarding the material management process. Finally, some recommendations, solutions to overcome the flaws and concluding remarks have been drawn based on the study in Chapter four.
© 2005 sapficoconsultant com. All rights reserved. No part of this e-book
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or mechanical including photocopying, recording or by any information
storage retrieval system without permission in writing from
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“SAP” is a trademark of SAP Aktiengesellschaft, Systems, Applications and
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SAP AG is not the publisher of this e -book and is not responsible for it under
any aspect.
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TABLE OF CONTENTS
INTRODUCTION.........................................................................................................4
1. Maintaining Material Master for Product costing ...............................................5
1.1 Raw and Packing material ..............................................................................5
1.2 Finished good................................................................................................. 16
2. Bill of Material (BOM)...........................................................................................26
3. Activity prices maintained for cost centers .......................................................33
4. Resource/ Work center ........................................................................................37
5. Master Recipe/ Routing .......................................................................................40
6. Production versions .............................................................................................46
7. Maintain Overhead rates ....................................................................................55
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INTRODUCTION
In this e-book we cover the various master data required for the product
costing module. Most of the master data is dependent on the Production
planning module (PP module).
It is imperative for a Product costing consultant to understand the master data
created in the Production planning module and its implications on product
costing.
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1. Maintaining Material Master for Product costing
1.1 Raw and Packing material
The importa nt views in the material master for the product c osting module are
the accounting and costing view in raw and packing material.
We will see how to maintain the accounting and costing view for raw material.
The raw material 9100-202 is used in the manufacture of final product 9100103.
These views are maintained by the Finance and the costing department.
Use transaction code: MM01
Or
Path:
SAP standard menu à Logistics à Materials Management à
Master à Material à Create (General) à MM01 - Immediately
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Material
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Click
Click
Select Accounting and costing views
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Update the following:-
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Update the following:-
Click
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Update the periodic unit price (moving average price). This price is picked up
as the price for the raw material (depending upon the setting maintained in the
costing variant) when the standard cost estimate is executed for the finished
product.
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Click
Update the valuation class for raw material
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Click
You need to select
This tic k should be selected because system will calculate standard cost
estimate for raw material and packing material as well. We do not want
system to calculate standards for raw and packaging material hence we select
do not cost.
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We select this since we cost our finished product with a quantity structure.
This indicator must be selected, whereby the material number will be written
to the cost element itemization in the controlling module. This enables us to
analyze material costs in the information system in more detail.
Update the profit center field.
Where different overhead rate are applicable on different raw material then
you need to update the relevant overhead group in the field
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Click
The raw material prices can also be maintained in the planned price1, 2 or 3
fields and can be picked up as prices during the standard cost estimate
calculation of the finished product. This depends on the configuration setting
in the costing variant.
Click on
to save the material master
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1.2 Finished good
Let us now see the material master creation of Finished good.
Use transaction code: MM01
Or
Path:
SAP standard menu à Logistics à Materials Management à
Master à Material à Create (General) à MM01 - Immediately
Material
The important views for finished goods are MRP 2, MRP 4, Accounting and
costing view.
The MRP views are maintained by th e Production planning (PP) guys.
It is imperative for a product costing consultant to know these views.
Click
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Click
and also select
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Click
Update the following:-
Click
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Update the following:-
Click
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Select the Procurement type as
In case of manufactured E should be updated.
The field
is very important in case the finished
goods are stock transferred to another plant which is a depot or a selling
plant.
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Let us take an example:Finished goods 9100-103 is manufactured in plant 9100. The Bill of Material
and Master recipe are maintained in plant 9100. Therefore the standard cost
estimate is calculated in plant 9100.
This product is stock transferred to another plant 9101 which is a sales depot.
There exists no BOM and master recipe in plant 9101.
How to do you calculate the standard cost estimate in plant 9101?
Here special procurement key is of prime importance. The special
procurement key is configured in material requirement planning.
It basically tells the system that plant 9101 will receive material from plant
9100.
Thus when you execute standard cost estimate for the product 9100-103 in
plant 9101, if a special procurement key has been maintained in the material
master in plant 9101, then the standard cost estimate is transferred from plant
9100 in plant 9101.
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Click
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Production versions are maintained in this view. Production
version is basically a combination of a Bill of Material and Master recipe.
Finished goods can have various production versions. But when a standard
cost estimate is executed the product cost planning component by default
picks up only the first production version.
In case a product is manufactured using repetitive manufacturing then the
following fields are updated.
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Click
Update the valuation class and the price control S for the finished goods.
No price needs to be maintained here, since the product costing module will
calculate the price for the finished good.
Click
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Select
Also ensure that the variance key is in place. Normally this is defaulted based
on the configuration settings maintained in OKVW.
Update the relevant profit center.
Also update the costing lot size: Lot size in which the product is costed.
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Click
Click on
2. Bill of Material (BOM)
A finished product is manufactured using various components i.e. raw and
packaging material.
This list of component that makes the final product is called the Bill of
Material. It contains the object number of each component with quantity and
unit of measure. The components are known as BOM items.
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We will display a BOM which is created by the Production planning
department.
Transaction code: CS03
Or
SAP menu à Logistics à Production à Master Data à Bills of Material à
Bill of Material à Material BOM à CS03 – Display
Update the following:-
Click
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Click
to see the header of the BOM
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In header the Base Quantity of the finished good is mentioned. This should be
in sync with the costing lot size. The base quantity is 1000 above whereas in
the material master it is 1, therefore we should change the costing lot size in
the material master to 1000.
Click
to the item details
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There is only one component 9100-202 used in the manufacture of 9100-103
Double click
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on the component
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Click
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The Costing relevancy selection is important. This selection controls whether
the component is relevant for product cost estimate or not.
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3. Activity prices maintained for cost centers
The activities typically carried on a product could be as follows:Machine activity
Labour activity
Quality checking activity
Activity prices are maintained for each of the above activity. These activities
are carried out by various production cost centers.
The activity costs are absorbed into the product as follows:Activity Qty (mentioned in the recipe or routing) X activity price (maintained for
activity type and cost center combination)
Before we maintain let us see a cost center report for cost center 9101012
using transaction code S_ALR_87013611 - Plan/Actual Comparisons
The total cost planned on the cost center is 840, 000.
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This cost needs to be absorbed into the product.
Now let us proceed for updating the activity price
Let us see the how the activity prices are maintained in the cost center
accounting module:
Transaction code: KP26
Or
Menu Path:
SAP Menu → Accounting → Controlling → Cost Center Accounting → Planning
→ Activity Output/Prices → KP26 – Change
We will maintain plan activity price for activity labour and the labour cost
center for the year 2007.
Update the following:-
Click
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Update the following:The planned labour hours (activity) for the year 2007 is 70,000 hours.
The activity price calculated works out to 12/- which is as follows:Activity price = Total cost on Labour cost center
-------------------------------------------Planned activity
= 840,000
------------70,000
= 12/-
Let us update that as below
Click on
Let us now again see the cost center report using transaction code
S_ALR_87013611 - Plan/Actual Comparisons
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The cost of 840,000/- is now absorbed, showing 0.04- balance.
The plan activity of 70,000 hr is also updated on the cost center.
The above method is manually updating activity prices in the cost center
planning.
Another option is to have system calculate activity price through system. You
only maintain the activity output 70,000 hrs through the transaction KP26.
The activity price calculation is executed through transaction code KSPI Price Calculation.
System will automatically calculate price as follows:Activity price = Total cost planned on the cost center 9101012
---------------------------------------------------------------Activity output
= 840,000
-------------70,000
= 12/- per hour
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4. Resource/ Work center
A Resource is an organizational unit that defines where and when an
operation should be carried out. It has an available capacity. The activity
performed here is valuated by charge rates which are determined by cost
centers and activity types.
A Resource is a master data defined when process orders are used. Process
orders are used for process industry.
The same master data is defined as Work center when production orders are
used.
A Resource/Work center is linked to a cost center.
This master data is maintained by the PP guys.
The PP and CO teams have to jointly work to define and link the
resource and cost center.
Let u s display a resource.
Transaction code: CRC3
SAP menu à Logistics à Production – Process à Master Data à Resources
à Resource à CRC3 – Display
Update the following:-
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Click
The resource LABOUR is linked to cost center 9101012 and activity type
LABOUR
It is only possible to maintain the cost center and activity here, if it is
maintained in the earlier step KP26.
Position the cursor on
Click
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A formula maintained above helps in proportionately calculating the number of
hours required.
E.g. The number of hours required for a base quantity of 1000 kgs is 10
hours.
If the manufacturing batch size is 5000 kgs then as per the above formula the
number of labour hours is calculated as follows:= 10 hrs X 5000 kgs
------------1000 kgs
= 50 hrs
It is essential to verify that formula is correctly defined.
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5. Master Recipe/ Routing
A Master Recipe is a description of a specific process in the process industry
that does not relate to a specific process order.
It is used for producing materials.
The same master data is called as Routing when production orders are
used. Of course the maintenance of the 2 master data is through
different transaction codes. Master data to be maintained in both the
cases are more or less same.
The master recipe is maintained by the PP team.
Let us display the master recipe maintained for the finished product.
Transaction code: C203
Or
Menu Path:
SAP menu à Logistics à Production – Process à Master Data à Master
Recipes à Recipe and Material List à C203 – Display
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Update the following:-
Click
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Click on the
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The status of the master recipe must be 4 and usage 1.
Also check the Base quantity of the master recipe.
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Click on
There are 2 operations in the recipe
1) Machine hours
2) Labour hours.
Double click
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You find the activity type 1PDH01 is defaulted automatically from the resource
MACHINE. The number of machine hours required for base quantity of 1000
KG - 5 hrs is maintained here.
Click
Double click
You find the activity type LABOUR is defaulted automatically from the
resource LABOUR. The number of Labour hours required for base quantity of
1000 KG - 8 hrs is maintained here.
Click
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Also note the costing Relevancy indicator in the master recipe above
This determines that the operations are relevant for costing.
6. Production versions
A production version is a production technique that can be used to produce a
material.
It is a combination of a BOM and Recipe/Routing.
Let us take an example of what can be the difference between 2 production
versions to manufacture the same product:1) Production version 1
BOM - 1
Master recipe – 1
Master recipe 1 uses fully automated machines with latest technology. They
are high speed machines where the processing time is less i.e. 2 hours
Production version 1 uses BOM 1 and Master recipe 1 to manufacture the
product.
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2) Production version 2
BOM -1
Master recipe – 2
Master recipe - 2 uses machine with old technology which requires more
processing time and also is not automated therefore some labour operation is
also required.
The production version 2 uses BOM 1 and master recipe 2 to manufacture the
product.
You will have a question in mind why do we require the second production
version? Why not manufacture all the products using production version 1?
The answer to this question is there is limited capacity available on production
version 1. Therefore production version 2 needs to be used due to capacity
constraints in production version 1.
Production versions are maintained by the PP guys.
Let us see the creation of a production version.
Transaction code: MM02
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Click
Click
Update the following:-
Click
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Click
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Update the following:-
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Click
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Update the following:-
Click
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Click
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Click
Click
Click on
The first production version 1 is by default picked up while executing standard
cost estimate.
In case you want to have a Standard cost estimate taking the average of both
the production version you need to configure mixed costing.
Mixed Cost estimate configuration and master data maintenance is
covered in our SAP FICO configuration CD set.
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7. Maintain Overhead rates
In case overheads have been configured then you need to maintain the
overhead rates as a part of master data.
Overheads can be calculated as a % of Material costs or as a % of wages.
It can also be calculated based on quantity of raw material.
The overheads configured in our scenario are production overhead which is
4% of wages.
This is maintained by the costing department every year.
A costing sheet must have been configured for this to work. The
configuration of the costing sheet has been covered in detailed in the
Product costing CD of the SAP FICO configuration CD set.
Transaction code: S_ALR_87008275
Or
Path:
SAP menu à Accounting à Controlling à Product Cost Controlling à Cost
Object Controlling à Product Cost by Order à Period-End Closing à Current
Settings à S_ALR_87008275 - Define Percentage Overhead Rate
Select
Click
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Select
Click
Update for the year 2007
Click
Click on
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You are now ready to run the standard cost estimate, provided all the
product costing configuration is in place.
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