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Author's profile photo R Brahmankar

Resource Classification in Master Recipe for Planning

Often, many industries like FMGC, chemical, pharmaceutical, etc use multiple similar resources to manufacture a product.

E.g. A plant has many mfg bagger, or filling lines with identical capacities. A product is chronologically said to be manufactured in bagger 2. Alternatively this product also can be manufactured in bagger 3 or bagger 4 if needed. On shop-floor business cannot determine the primary resource to be used until shortly before order processing. But in mid to long term planning, they want to assign a suitable planning resource to the operations provisionally.

The constraint for long term planning needs to be on planning resources. In the short term the flexibility needs to be given for resource selection based on SKU. This can be mapped in different ways in SAP.

1. By multiple production Versions with multiple master recipe

This method is most widely used but requires laborious master data maintenance as one recipe has to be created explicitly for each resource and has to be assigned to one production version respectively.

2. By manual selection in the Order.

The resource is changed manually on the Order. This change requires a single approval process if ECM to be used. Production Planners will feel as more work and any change which needs a Quality Approval in GMP environments will take more time to create and release the order for production.

3. By Resource Selection through classification.

SAP provides another way of maintaining this alternate resource selection by using resource classification.

We can use a planning resource as the primary resource and select the alternate resource through the resource network maintained through work center classification (type 019). This also works well with ECM and is a good option for Planners as there is no need of Single Approval from QA personnel.

Create a Characteristic (T-Code CT04)

We can create classifications in ECC for suboperations and secondary resources.

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In Additional data tap define Table Name as CRHD and Field Name as ARBPL.

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Create Class and assign characteristics to class T Code: CL02

MD12.JPG

 

Assign classification in resource T Code: CRC1 or CRC2

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All relevant alternative work centers must contain exactly the same classification and characteristic value assignment. Work centers with different classes or characteristic values are ignored.

MD12.JPG

Assign the classification in master recipe and add alternate resources T Code: C201 or C202

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Create process order COR1 or By MRP Planned order to Process order

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On the operations tab, select the operation 10 and click on Resource selection condition

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Product can be produced on all 3 lines here you can select the resource accordingly.

Capacity Planning CM25

We can change the resource from this screen by dragging and dropping it to another resource from the resource section.

MD12.JPG

Resource classification automatically creates multiple modes in APO PDS or PPM, so it can be used in PPDS while converting SNP Plan orders to PPDS plan orders. And in DS board we can schedule the order on required resources.

MD12.JPG

If we want to use different capacities for planning, but for execution purposes we only want to use one resource. So from many lines in mid term planning to accommodate constraints, but for short term we use single resource for production execution.

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      59 Comments
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      Author's profile photo Anupam Sharma
      Anupam Sharma

      Hi Rupesh,

      Thanks for sharing your knowledge, We have been struggling with the previous two options in our projects with same problem.

      Great work.

      Regards,

      Anupam Sharma

      Author's profile photo R Brahmankar
      R Brahmankar
      Blog Post Author

      Thanks Anupam. 🙂

      Author's profile photo Mangalraj Senthamaraikannan
      Mangalraj Senthamaraikannan

      Hi Rupesh,

      Good Work and thanks for sharing.

      Regards

      Mangalraj.S

      Author's profile photo R Brahmankar
      R Brahmankar
      Blog Post Author

      Thanks a lot Mangalraj..!!

      Author's profile photo Former Member
      Former Member

      Great document. Good learning as well.

      Does address some concerns in proces industries.

      Author's profile photo R Brahmankar
      R Brahmankar
      Blog Post Author

      Thanks all for there compliments.

      Author's profile photo GYAN R
      GYAN R

      Hi Rupesh,

      Excellent document.Thanks for sharing.

      Regards,

      Author's profile photo Former Member
      Former Member

      Hi Rupesh,

      Nice document, very helpfull for PPPI

      Author's profile photo R Brahmankar
      R Brahmankar
      Blog Post Author

      Thanks Vishal Much appreciated.

      Regards,

      R.Brahmankar

      Author's profile photo M Manimaran
      M Manimaran

      Hi Rupesh,

      Thanks for sharing this useful info.

      Author's profile photo R Brahmankar
      R Brahmankar
      Blog Post Author

      Thanks for the compliment.

      Author's profile photo Vibin V Joseph
      Vibin V Joseph

      Thanks For sharing , Very Helpful document. Is it Possible that this functionality is possible in Discrete manufacturing..? Like in Textile , In weaving operations there are more than 50 Looms and they decide during the Production order generation.

      Author's profile photo R Brahmankar
      R Brahmankar
      Blog Post Author

      Hi Vibin,

      In Discrete manufacturing you can use the parallel or alternative sequence in routing.


      Regards,

      R.Brahmankar


      Author's profile photo Vibin V Joseph
      Vibin V Joseph

      Thanks Brahmankar

      Author's profile photo Sharat Sugur
      Sharat Sugur

      Dear Rupesh,

      Well explained, thank you for sharing.

      Regards,

      Sharat

      Author's profile photo R Brahmankar
      R Brahmankar
      Blog Post Author

      Thanks Sharat.

      Author's profile photo Former Member
      Former Member

      Hi Rupesh,

      The blog is very useful.

      Regards

      Prashanth

      Author's profile photo Caetano Almeida
      Caetano Almeida

      Hi Rupesh

      Thanks for sharing that. I'll add to my reference list.

      BR

      Caetano

      Author's profile photo R Brahmankar
      R Brahmankar
      Blog Post Author

      Thanks much Caetano..!!

      Author's profile photo Former Member
      Former Member

      Thanks Rupesh

      Author's profile photo Former Member
      Former Member

      Hello Rupesh,

      Thanks for this very useful Shared Doc,
      Is it will also helpful in Discrete ? as one our client also do the same activity while confirmation only.

      Best regards,

      Sujeet

      Author's profile photo R Brahmankar
      R Brahmankar
      Blog Post Author

      Hi Sujeet,

      Thanks, In Discrete manufacturing you can use the parallel or alternative sequence in routing.

      and while confirmation you can select alternative sequence.

      Regards,

      R.Brahmankar

      Author's profile photo R Brahmankar
      R Brahmankar
      Blog Post Author

      For  Discrete manufacturing :- Please refer below screen shot  for Operation classification with multiple work centers in routing.

      Capture.JPG

      Author's profile photo Debashis Padhy
      Debashis Padhy

      Hii Rupesh,

      We are using classification 19 for grouping of alternative resources, and then doing planning in APO. It moves as  a single PDS with multiple modes.

      The planning is perfect, and we never faced any problem, But recently we have started WMS, where we got the issue that Though APO Shows planned order/production order for particular Resource based,  But when it comes to ECC it doesn't show the correct resource for the planned order/production order.

      The Production order in ECC side does not give the correct information of resource. Even in the report COOIS , in the column production line , it doesn't show the correct information as per planned in APO.

      Is it possible to get the correct information resource in ECC side for the orders ?

      Regards

      Debashis

      Author's profile photo R Brahmankar
      R Brahmankar
      Blog Post Author

      Hi Debashis,

      I really don't have any idea about resource classification with WMS. You many raise this issue to OSS. Also update the solution over here.

      Many Thanks,

      R.Brahmankar

      Author's profile photo jagdish kumar
      jagdish kumar

      Hi Rupesh,  Thanks a lot for sharing the knowledge.  Regards, Jagdish

      Author's profile photo arturo senosain
      arturo senosain

      Nice doc.

      Thanks for share.

      Arturo.

      Author's profile photo shailesh mishra
      shailesh mishra

      Dear Rupesh,

      Thanks. Document is very informative and actually I am on a Implementation Project where 200 Reactors( Resources) and their usage unpredictability were creation a chaos and I was Struggling.

      Perhaps, one more way could be from Standard SAP customization of Single Entry of Confirmation OPK1 where we can create an alternate Profile encapsulating Actual Resource. At the time of Process Order creation, default Resource will be used but at the time of Confirmation, Actual resource will be Capitalized.( Bottom of COR6N screen)

      Next screen Looks like this

      Click on preview will navigate to next screen.

      There will be Actual resource from where we can confirm the Order. All the Activities will be loaded from default resource to Actual Resource. And Variance can be analyzed as Resource Usage Variance in Controlling.

      Regards

      Shailesh

      Author's profile photo R Brahmankar
      R Brahmankar
      Blog Post Author

      Hello Shailesh,

      This is really a good option too. Please create a document and post it on SCN. It will be helpful to everyone.

      Thanks,

      R.Brahmankar

      Author's profile photo Mariano Cabalen
      Mariano Cabalen

      Hi Rupesh,

      Good Work!!

      Thanks and Regards,

      Mariano

      Author's profile photo R Brahmankar
      R Brahmankar
      Blog Post Author

      Thanks a lot Mariano. 🙂

      Author's profile photo shailesh mishra
      shailesh mishra

      Dear Rupesh,

      In comments, you have mentioned that Work center classification is too applicable in Discrete Industry. I tried and tested the results but while assigning the multiple work centre in Routing, it is not accepting. Though multiple Work centers do appear in operation but you cannot this concept in Discrete industry. You may also test this and correct me if I am wrong.

      Best Regards

      Shailesh Mishra

      Author's profile photo R Brahmankar
      R Brahmankar
      Blog Post Author

      Hello Shailesh,

      As I know it should work, could you please let me know what the issue you are facing?

      Best Regards,

      R.Brahmankar

      Author's profile photo shailesh mishra
      shailesh mishra

      Dear Rupesh,

      Class and characteristics created for 3 work centre WC1, WC2, WC3 and in Cr02 assigned the class.

      Now, while assigning classification to Operation 10, Not all 3 work centres are getting assigned.

      When you are about to assign multiple Work centre to Op-10, this functionality is missing in discrete as system allows to assign only 1 work centre to operation.

      Please correct me if I am wrong.

      Best regards

      Shailesh

      Author's profile photo R Brahmankar
      R Brahmankar
      Blog Post Author

      Hello Shailesh,

      This could be due to Characteristic only allowed for Single value.

      Go to CT04 enter your Characteristic in Basic data Choose Multiple value radio Button.

      Then again assign class RESOURCE_ALT to your work center system will allow you multiple work centers.

      Best Regards,

      R.Brahmankar

      Author's profile photo shailesh mishra
      shailesh mishra

      Dear Rupesh,

      100% correct. It worked as you said. Thanks a lot once again for clearing my doubt.

      In discrete industry, we too can use Resource selection Condition for Operations.

      Best regards

      Shailesh

      Author's profile photo R Brahmankar
      R Brahmankar
      Blog Post Author

      Hello Shailesh,

      Thanks for your confirmation. 🙂

      Best Regards,

      R.Brahmankar

      Author's profile photo Dhaval Choksi
      Dhaval Choksi

      Hi Rupesh,

      Very good document, thanks for sharing.

      Br

      Dhaval

      Author's profile photo R Brahmankar
      R Brahmankar
      Blog Post Author

      Hello Dhaval,


      Thanks a lot and welcome back to SCN. 🙂

      Best Regards,

      R.Brahmankar

      Author's profile photo Former Member
      Former Member

      Hi Rupesh,

      We are using resource network for the same requirement.

      Is there any way to restrict the change of resource in Capacity Planning (CM25) to another resource that not in the classification?

      Author's profile photo R Brahmankar
      R Brahmankar
      Blog Post Author

      Hello,

      Please refer OSS kBA 2142971 - Authority check on CM25 and general capacity leveling transactions

      Best Regards,

      Rupesh

      Author's profile photo TRAORE TIDIANE
      TRAORE TIDIANE

      Hi Rupesh,

      Is there a way (usex exit or function) to update standard values of operation when changing the work centre? To be clear how to reschedule operation(duration of operations)  when alternatives ressources have not the same speed ?

      thanks for your help

      Author's profile photo Former Member
      Former Member

      Hi Traore,

      Did you find any solution or a work around for Alternate Resources having varying Speeds?

      Thanks & regards,

      NH

      Author's profile photo TRAORE TIDIANE
      TRAORE TIDIANE

      Hi NH

      Unfortunately i found no solution or work around. Still searching.

      Regards

      Author's profile photo Former Member
      Former Member

      Hi Rupesh,

      Great work! It is very helpful.

      Thanks a lot!

      Marcos

      Author's profile photo Rohan Somji
      Rohan Somji

      Very useful document Rupesh. Thanks a lot..

       

      Regards,

      Rohan

      Author's profile photo Javier Cotua
      Javier Cotua

      Very useful document.

       

      Do you know any way to synchronize all activities between modes?.   I have a case where all alternatives modes work simultaneously because they pack the same semi-finish in different brands of finish products.

      Author's profile photo Johnny Leguia
      Johnny Leguia

      Hi Rupesh,

       

      In this case when i´m going to make a finite capacity planning, the order consider the sumarize capacity of the individual resources?...

       

      Regards from Lima-Perú.

      Johnny Leguia

      Author's profile photo R Brahmankar
      R Brahmankar
      Blog Post Author

      Hello,

      It depend upon the resource master setting as finite or infinite, yes system should consider the summarize capacity of the individual resources.

      Best Regards,

      R.Brahmankar

      Author's profile photo Hanumantharao Chintalapudi
      Hanumantharao Chintalapudi

      Very nice document

      Author's profile photo Sai Kumar
      Sai Kumar

      Dear Rupesh Sir,.

      Your document was self explanatory, but I have issue when I followed the same steps and mentioned the issue below.

      Dear Rupesh Sir,

      Your document is self explanatory, I too followed the same process but I have some issues as mentioned below.

      We are facing an issue while we are planning on alternative resources.
      we have classified the resource using class type 019 and assign that class to the operation in master recipe.

      while defining the class in the master recipe we have defined the alternative resources which planner can plan for certain SKU’s.

      But in the planning board (CM25) when we drag and drop the orders on other resources apart from the classified, it is still allowing to do so.

      How can we prevent orders planning on wrong resources?

      Please guide me sir, this has become very critical.

      Thanks in advance

      On%20the%20operations%20tab%2C%20selected%20the%20operation%200040%20and%20click%20on%20Resource%20selection%20condition%2C%20the%20alternate%20resource%20option%20is%20popping%20out%20for%20selection

      On the operations tab, selected the operation 0040 and click on Resource selection condition, the alternate resource option is popping out for selection

      Expectation%20is%20order%20777123%20and%20777124%20should%20allow%20drag%20and%20drop%20on%20only%20between%20MELT1%20MELT2%20MIX1%20MIX2

      Expectation is order 777123 and 777124 should allow drag and drop on only between MELT1

      MELT2 MIX1 MIX2

       

      But%20it%20is%20allowing%20to%20drag%20it%20on%20other%20resources%20as%20well%20like%20C199MIX%20C200MIX%20etc.%20Which%20is%20not%20feasible.

      But it is allowing to drag it on other resources as well like C199MIX C200MIX etc. Which is not feasible.

       

      Author's profile photo R Brahmankar
      R Brahmankar
      Blog Post Author

      Hello,

      For your strategy profile ZPPI_G001 check if you have set

      Reschedule with production versions
      Terminate when resched.with prod.version rescheduling

      Not sure if it will work for process order however planned order it should.

      So in CM21/CM25, enter a work center/resource  belongs to classification (e.g. work center / resource

      MELT1MELT2 MIX1 MIX2) and a work center that does not belong do not select that.

       

      Or check user exit CY190001 FM EXIT_SAPLCY19_001 User exits to change order operation where you can valid the classified resource.

      Best Regards,

      R.Brahmankar

      Author's profile photo Farid Azzi
      Farid Azzi

      Excellent work R Brahmankar

       

      Thank you for sharing such a great content.

       

      Regards.

      Farid.

      Author's profile photo R Brahmankar
      R Brahmankar
      Blog Post Author

      Thanks a lot Farid Azzi

      Author's profile photo Zev Yang
      Zev Yang

      Hi,R Brahmankar:

      Is this operation only valid in process order ? I couldn't see this option in production order. thanks.

      On the operations tab, select the operation 10 and click on Resource selection condition

      Author's profile photo R Brahmankar
      R Brahmankar
      Blog Post Author

      Hello Zev,

      In Discrete manufacturing you can use the parallel or alternative sequence in routing too
      Nonetheless you can also try the operation classification, from that please refer my comment on dated February 14, 2014 at 7:03 am

      Best Regards,

      R.Brahmankar

      Author's profile photo Zev Yang
      Zev Yang

      Hi,R Brahmankar:

      Your comment on "dated February 14, 2014 at 7:03 am" show how to assign the characteristic value in routing CA02.

      But how to change the work center in production order? I couldn't find the option to change the characteristic value in production order ,and trigger the work center replacement in production order.

       

      thanks.

      Author's profile photo Rajesh Gurrala
      Rajesh Gurrala

      Dear Rupesh,

      Thanks for such detailed explanation, as I am trying the solution to discrete manufacturing and facing an issue in choosing the work center in production order for selection function under operation overview.  I didn't find any option to choose the work center for operation 10.

       

      Dear https://people.sap.com/shailesh.mishra5.

      With reference to your comment dated on March 18th  2015 Can you please help how it worked for discrete manufacturing? How you have chosen the work center characteristic value in production order before release?

       

      Dear https://people.sap.com/monst.yang

      Please assign the same class to all relevant work centers first and then go to routing under operation view , Go to extras and choose classification. There you can assign all work centers as characteristic values. If you face any information pop-up for class type conversion please run the program for class type 019 and it will work.

       

       

       

      Best Regards,

      Rajesh G

       

      Author's profile photo R Brahmankar
      R Brahmankar
      Blog Post Author

      Hello Rajesh,

      There is no option for an operation classification in production order. However you can exchange the operation sequence you can use the alternative sequence or parallel operation. Also order split also supported in discreate manufacturing. Nonetheless,  if you are using PPDS you can use the alternative mode from PDS to schedule your order on different resources.

      Best Regards,

      R.Brahmankar