PTP SO01 Sewing Order Creation and Confirmation.pptx

PTP SO01 Sewing Order Creation and Confirmation.pptx

1. PTP-SO-01: Sewing Order Creation & Confirmation FRS Session – 04/25/2019 FRS Session PTP-SO-01: Sewing Order Creation & Confirmation

2. PTP-SO-01 Sewing Order Creation & Confirmation Workshop Lead: Shehan Abeyagunawardene FRS Session PTP-SO-01: Sewing Order Creation & Confirmation

3. AGENDA INTRODUCTION HOUSEKEEPING OVERVIEW SEWING ORDER CREATION PRODUCTION VERSIONS SEWING CONFIRMATIONS QUALITY MANAGEMENT OTHER SHOP FLOOR RELATED PROCESSES FRS Session PTP-SO-01: Sewing Order Creation & Confirmation

4. HOUSEKEEPING PLEASE ENSURE THERE IS ONLY 1 CONVERSATION AT A TIME DURING THE SESSION MEETING MINUTES WILL BE DISTRIBUTED WITHIN 48 HOURS OF THE SESSION DON’T BE AFRAID TO ASK QUESTIONS HEALTHY CHALLENGING DEBATE IS POSITIVE HELP FACILITATOR CAPTURE DECISIONS OR GAPS CORRECTLY DEVICES SHOULD BE KEPT TO A BARE MINIMUM SO THAT EVERYONE CAN FOCUS ON THE DESIGN SESSIONS FRS Session PTP-SO-01: Sewing Order Creation & Confirmation

5. Overview FRS Session PTP-SO-01: Sewing Order Creation & Confirmation

6. Sewing Orders: Overview This workshop covers the following topics that pertain to the sewing function: Sewing order creation Sewing order confirmations Post production planning and subsequent to cut operations the sewing process takes place There could also be additional operations post sewing which have to be confirmed in order to complete the manufacturing process FRS Session PTP-SO-01: Sewing Order Creation & Confirmation

7. Where Are We in the End to End Process? Sew Order Creation and Confirmation FRS Session PTP-SO-01: Sewing Order Creation & Confirmation

8. Sewing: SAP AFS vs. S/4 Fashion Sewing and other related operations are defined / processed in terms of production orders both in AFS and S/4 Fashion S/4 Fashion provides the facility to integrate the system with third party shop floor systems to send / receive data objects pertaining to production orders Production order creation and confirmations are executed with respect to a master production order in S/4 Fashion Each variant article in S/4 (SKU in AFS) has its own production order FRS Session PTP-SO-01: Sewing Order Creation & Confirmation

9. Sewing Order: Production Order Creation FRS Session Production order creation in S/4 Fashion could done by converting a planned order The material components required for production are contained as items in the planned order and are copied directly when the planned order is converted to a production order Order types could be defined through customizing for production orders A number range will be associated with each production order type The production order will inherit a ‘production version’ from the planned order at the point of conversion PTP-SO-01: Sewing Order Creation & Confirmation

10. Production Versions FRS Session A Production Version forms the link between the Bill of Material (BOM) of a product and it’s Routing There may be different production versions based on the lot sizes and validity dates PTP-SO-01: Sewing Order Creation & Confirmation

11. Production Versions FRS Session Each version has the alternative BOM number and routing Group number associated with it PTP-SO-01: Sewing Order Creation & Confirmation

12. Production Versions FRS Session The lot size range, Task List Type, Group, validity period, etc. should be maintained PTP-SO-01: Sewing Order Creation & Confirmation

13. Production Versions FRS Session The production version could be assigned to both planned orders and production orders PTP-SO-01: Sewing Order Creation & Confirmation

14. Production Versions FRS Session The production version gets assigned to a production order when the order is created by converting a planned order PTP-SO-01: Sewing Order Creation & Confirmation

15. Sewing Order: Stock Requirements List FRS Session Sewing orders created could be viewed through the Stock Requirements List PTP-SO-01: Sewing Order Creation & Confirmation

16. Sewing Order: Production Order Status FRS Session SAP assigns order statuses to production orders to reflect the current status of the production order PTP-SO-01: Sewing Order Creation & Confirmation

17. Sewing (Production) Order: REL Status FRS Session In order to process a production order in SAP the order has to be released By releasing a production order the following activities could be carried out with regard to production orders: Confirmations for the order could be executed Goods issues with respect to the production order could be done Shop floor papers could be generated An order may be released upon creation if preparation time for the order is not required Generally the responsibility of order release lies with the planning department PTP-SO-01: Sewing Order Creation & Confirmation

18. Sewing (Production) Order: TECO Status FRS Session TECO status refers to the status of technically completing a production order that has completed the production run or has pre-maturely ended Once technically completed no further goods movements can be done using the relevant production order Technically completed production orders will not be listed in the Stock Requirements List Production orders with status TECO are no longer considered during an MRP run Once TECO status is activated the controlling department could execute the variance calculation for the production order PTP-SO-01: Sewing Order Creation & Confirmation

19. Sewing (Production) Order: Component Details FRS Session The bill of material components could be viewed through the production order PTP-SO-01: Sewing Order Creation & Confirmation

20. Sewing (Production) Order: Operation Details FRS Session Routing operations are displayed in the production order in the Operation Overview screen PTP-SO-01: Sewing Order Creation & Confirmation

21. Sewing (Production) Order: Read PP Master Data FRS Session Any changes to the bill of material or routing could be picked to the production order post conversion through the ‘Read PP Master Data’ function Picking the above changes is only possible if goods issues and confirmations for the relevant production order have not been carried out PTP-SO-01: Sewing Order Creation & Confirmation

22. Sewing (Production) Order: Duration of Order FRS Session The duration of the production order (order run) is provided in terms of start/end dates in the production order PTP-SO-01: Sewing Order Creation & Confirmation

23. Sewing Order: Subcontracted Operations FRS Session In parallel to sewing operations there could be operations that are outsourced to third party vendors e.g. printing, embellishing, etc. These operations could be included in the set of routing operations of the article The quantities sent out and received in could be captured through a barcode scan or QR code scan PTP-SO-01: Sewing Order Creation & Confirmation

24. Sewing: Raw Material Issuances / Consumption FRS Session Raw material consumption and issuances may be done through any of the following methods through the system: Backflushing Manual issuances through standard transactions Raw material issuances take place based on a picking list PTP-SO-01: Sewing Order Creation & Confirmation

25. Sewing Order: Picking List A picking list could be used to request raw material components from the RM stores The picking list could be generated with respect to a sewing production order The S/4 Fashion system offers a standard picking list document Most organizations running SAP develop a customized format for the picking list Cut bundles could also be issued to sewing based on the picking list FRS Session PTP-SO-01: Sewing Order Creation & Confirmation

26. Sewing Order: Picking List A Sewing Picking list could be generated and sent to the warehouse to pick materials FRS Session PTP-SO-01: Sewing Order Creation & Confirmation

27. Sewing: As-Is Process at Carhartt FRS Session PTP-SO-01: Sewing Order Creation & Confirmation

28. Sewing: As-Is Process at Carhartt FRS Session PTP-SO-01: Sewing Order Creation & Confirmation

29. Sewing: Confirmation of Sew Operation FRS Session The confirmation of the sew operation could be handled through the following methods: Manual confirmation using the standard S/4 transaction code An enhancement that scans the operation barcode or QR code By confirming the sew operation in the system the following may occur: Finished Goods stock is created The sew milestone operation is complete in the routing and the subsequent operation is ready to be confirmed PTP-SO-01: Sewing Order Creation & Confirmation

30. Confirmations: Integration with 3 rd Party Applications FRS Session The S/4 system could be interfaced with a third party application to capture the output quantities The barcodes / QR codes for output quantities would be scanned using the third party application The figures captured through the third party application would be exported to the S/4 system S/4 would replicate the output captured through a background confirmation by invoking the standard confirmation transaction The syncing of the two systems should occur periodically throughout the day PTP-SO-01: Sewing Order Creation & Confirmation

31. Sewing: Confirmation of Sew Operation FRS Session The following data objects will have to be exchanged between the two systems: Article Plant Master production order number Production order number (size) Operation number Work center Confirmed quantity Confirmed date Confirmed time Shift PTP-SO-01: Sewing Order Creation & Confirmation

32. Confirmations: Other Operations FRS Session There may be numerous operations that form part of the routing of a finished product other than sewing These operations may include: Line In Launder Pressing Finishing Packing Accepted Quality Level (AQL) Each of the above operations will have its own barcode or QR code to be scanned PTP-SO-01: Sewing Order Creation & Confirmation

33. Production Control Workbench FRS Session S/4 Fashion provides a workbench through which numerous shop floor control transactions could be executed The workbench is referred to as the Production Control Workbench (PCW) The PCW screen could be accessed using t-code FSH_PCW PTP-SO-01: Sewing Order Creation & Confirmation

34. Production Control Workbench FRS Session The PCW screen displays the master orders associated with each planned order PTP-SO-01: Sewing Order Creation & Confirmation

35. Production Control Workbench FRS Session Planned orders could be converted to production orders through the Production Control Workbench PTP-SO-01: Sewing Order Creation & Confirmation

36. Production Control Workbench FRS Session The PCW screen displays the master orders associated with each production order PTP-SO-01: Sewing Order Creation & Confirmation

37. Production Control Workbench FRS Session Confirmations and goods issues pertaining to production orders could be executed using the PCW PTP-SO-01: Sewing Order Creation & Confirmation

38. Production Control Workbench FRS Session The PCW screen provides the facility to confirm individual operations of a production order and to reverse (cancel) the confirmations PTP-SO-01: Sewing Order Creation & Confirmation

39. Confirmations: Impact of Confirmations FRS Session The following activities may occur as a result of a confirmation in the system: Order data gets updated in terms of quantities, activities, dates and status Raw material components are backflushed Goods receipt occurs Costs get updated based on confirmations Generation of quality notifications (subject to customizing) Re-work functionality is triggered PTP-SO-01: Sewing Order Creation & Confirmation

40. Sewing Confirmations: As-Is Process at Carhartt FRS Session PTP-SO-01: Sewing Order Creation & Confirmation

41. Sew Order: Second Quality Garments & Rejects Second quality garments and rejects have to be identified A separate barcode or QR code is required to identify seconds and rejects The quality audit process will be carried out during sewing (in-line) as well as at the end of the sewing line (end-line) For finished goods sourced through vendors the quality inspection would occur at the receiving distribution center FRS Session PTP-SO-01: Sewing Order Creation & Confirmation

42. Sewing QI: As-Is Process at Carhartt FRS Session PTP-SO-01: Sewing Order Creation & Confirmation

43. Sewing Order: Planned vs. Actual Costs Upon confirmations taking place the variance between the planned and actual costs are captured through the system FRS Session PTP-SO-01: Sewing Order Creation & Confirmation

44. Other Shop Floor Related Functions / Processes FRS Session There are numerous processes allied to the shop floor area: Downtime Employee Movement Incentive Payments Employee Skills Machines and Attachments The above processes could be integrated with the S/4 system if required PTP-SO-01: Sewing Order Creation & Confirmation

45. Sewing: As-Is Process at Carhartt FRS Session PTP-SO-01: Sewing Order Creation & Confirmation

46. Sewing: Pain Points FRS Session What are the current pain points with regard to the following: Sewing Other operations (Launder, Finishing, etc.) Quality inspection PTP-SO-01: Sewing Order Creation & Confirmation

47. FRS Session RICEF Discovery PTP-SO-01: Sewing Order Creation & Confirmation

48. R I C E F FRS Session RICEF List: Does Carhartt use or require any specific enhancements and reports with regard to Sewing Order Creation and Confirmations? PTP-SO-01: Sewing Order Creation & Confirmation

49. R I C E F: Order Reconciliation FRS Session PTP-SO-01: Sewing Order Creation & Confirmation

50. FRS Session Q & A Session PTP-SO-01: Sewing Order Creation & Confirmation

51. FRS Session t h a n k y o u PTP-SO-01: Sewing Order Creation & Confirmation