PP End User Manual
PP End User Manual
USER MANUAL
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DOCUMENT INFORMATION
Project Name Document Name Document Location
Project Moves Ahead Production Planning User Manual
DOCUMENT HISTORY
Version Document Name Date Author Reviewed BY Change
Control
1.0 Production Planning
User Manual
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Production Planning – User Manual
TABLE OF CONTENTS
1.....................................................................PRODUCTION PLANNING - OVERVIEW
....................................................................................................4
1.1 Introduction to SAP and ERP concept....................................................4
1.2 Views with in SAP..............................................................................4
1.3 SAP’s Production Planning...................................................................5
1.4 AYSIC PP - Organization Structure.......................................................6
2 SAP LOGIN......................................................................................8
3 PRODUCTION PLANNING - MASTER DATA.........................................20
3.1 Material Master................................................................................20
3.2 Bill of Material.................................................................................47
3.3 Work Center....................................................................................59
3.4 Routing..........................................................................................81
3.5 Production version...........................................................................98
4 DEMAND MANAGEMENT...............................................................107
4.1 Create Demand Management – Pipes & Tubes....................................107
4.2 Change Demand Management – Pipes & Tubes..................................111
4.3 Display Demand Management – Pipes & Tubes...................................115
5 MRP-MATERIAL REQUIREMENT PLANNING......................................119
5.1 MRP Run at Plant Level...................................................................119
5.2 MRP Run at Material Level...............................................................140
6 CAPACITY PLANNING....................................................................148
6.1 Capacity Evaluation........................................................................148
6.2 Capacity Leveling...........................................................................157
7 SHOP FLOOR EXECUTION..............................................................162
7.1 Create Production Order..................................................................162
7.1.1 Convert Planned Order to Production Order....................................162
7.1.2 Create Production Order Manually.................................................175
7.2 Production Order Release................................................................180
7.3 Production Order Confirmation.........................................................189
7.4 Production Order Cancellation..........................................................199
8 RESERVATION & COST CENTER CONSUMPTION...............................214
8.1 Reservation...................................................................................214
8.1.1 Create Reservation......................................................................214
8.1.2 Change Reservation....................................................................219
8.1.3 Display Reservation.....................................................................222
8.2 Material Transfer (Transfer Posting)..................................................225
8.3 Scrap Generation through Cost Center..............................................239
9 REPORTS.....................................................................................244
9.1 Production Order Information System...............................................244
9.2 Daily Production Report..................................................................254
9.3 Stock Reports................................................................................257
9.3.1 Stock on Posting Date..................................................................257
9.3.2 Warehouse Stock........................................................................260
9.3.3 Material Document List................................................................263
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There are several views of SAP, from both the developers and the user’s
perspectives. These views include the:
Functional view: which is enables the user to access and use the functions
within SAP.
The “Configuration” view: Which is mostly accomplished through SAP’s
Implementation Guide (IMG). This is used primarily used by SAP consultants
in configuring SAP.
The ABAP Workbench: is used by developers to create code routines in the
ABAP language that add new functionality to SAP.
The Production Planning and Control in SAP addresses the planning and production
control needs of AYSIC, on a day-to-day basis (i.e. tactical or operative level) as
well as in the medium and Long Term (Strategic Planning).
Enterprise Structure
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Plant
Code Description
1000
2000
3000
4000
The Storage Location have been bifurcated and codified in the following:
Storage Location
Code Description
1100 Raw Material Store
1200 Semi Finished Store
1250 Production Store
1300 Finished Goods Store
1301 FG 2nd Quality Store
1310 Return Goods Store
1400 Spare Parts Store – Common
1401 Spare Parts Store – Mechanical
1402 Spare Parts Store – Electrical
1403 Spare Parts Store – Production
1500 Lubricants Store
1501 Gas Storage Store
1502 General Items Store
1503 Tools Stores Store
1504 Safety Store
1505 Packing Stores
1600 Scrap Stores
1700 Recycle Stock Store
2 SAP LOGIN
Purpose
You can log on to the portal from any client machine, with the user name and
password you use to access the company network, as defined in the corporate
server. Contact your administrator if you have any problems or questions.
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The SAP Logon is a Windows program, which you use to log on to SAP systems on
your Windows PC. It mediates between the SAP system and the SAP GUI user
interface. The SAP Logon displays a list of available SAP systems.
Double-click the SAP Logon icon on your desktop, SAP Logon Pad will appear
as screen given below:-
Enter Client
Enter User ID
Password
Language
3. By Area Menu
Go to System
End Session
Help on a field: - Explanation of the use of a particular field in cases where the
field labels is not self-explanatory.
Position the cursor on the field and choose or press the F1 key.
Click the message short text or position the cursor on the message short text and
F4 help opens up a dialog box and provides selection options of the field.
If you want to end your portal session, it is recommended that you click Log Off in
the masthead, and not simply close your browser. Closing the browser leaves the
portal still working, until it times out.
Command Fields:
/N = Terminate Current Session
/O = Keep Current Session & Open new Session
/NEX = Terminate All the open sessions & Logoff without warning.
SU53 = If Authorization is missing (Keep screen shot of SU53 after
executing Transaction & send to Help Desk)
Overview:
A material master contains all the information related to materials that procured,
produced, sold and stored. Material master has various views. Each function i.e.
Manufacturing, Purchase etc, has its own view of the material master. The material
master views relevant for Manufacturing are
Basic Data
MRP views
Work Scheduling View
Plant Data Storage 1
Plant Data Storage 2
Basic data views are maintained at client level and MRP data & Work Scheduling
views are maintained at a Plant level.
Material master Create transaction is used for creating a ‘New Material Code’ as well
as for ‘Creating a specific view for a specific organization entity’ e.g. Creating an
MRP view for a new manufacturing plant although the MRP data already exists for
other manufacturing location.
Basic Data: Views- Specify the Material description, Base Unit of measure, Material
Groups & Product hierarchy
MRP 1: View – Specifies MRP procedure, Lot sizing procedure and stocking norms
MRP 2: View – Specifies Procurement time, Safety stock requirements and Lead
times
MRP 3: View – Is relevant only for Demand management and sales planning
Work Scheduling – Specifies the data relevant for Production order like Delivery
tolerances etc.
Plant Storage data1 – If the unit of issue is different than the base unit of measure
then, specifies the unit of issue in the plant data storage.
Plant storage data 2 – Profit center will be maintained in the plant data storage 2.
Profit center is equal to plant code i.e. 1000
Press Enter.
Select views as
per material
type.
Note- The material type controls the material views. Therefore, specific material types
will not contain certain views.
Press Enter
Press Enter
Sales Division
Press Enter
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Press Enter
Press Enter
Press Enter
planning a
material.
Availability Availability check – R Daily Requirement – ‘01’
Check Specifies whether
and how the
system checks
availability and
generates
requirements for
materials planning.
R = Required, O = Optional, C = Conditional
Press Enter
Select collective
requirements only - 2
Press Enter
Press Enter
Press Enter
System will show the message with material number as material 15000000213 created.
Enter the material number which company needs to change the data.
Select Enter.
Press Enter.
After selection, system will bring you to relevant screen. Change the data and save. Selection
process is same as the material master-creation procedure.
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Select Enter
Select Enter
Overview:
A bill of material is a complete, formally structured list of the components that make up a
product or assembly. The list contains the object number of each component, together with
the quantity and unit of measure. The components are known as BOM items
Bills of material (BOMs) contain essential master data for integrating materials management
and production control.
Press Enter
Select all BOM component by select all icon . After selecting, the icon system will select
all components as shown in below screen
Select Enter
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Enter Material
Number
Enter Plant
Select Enter
Select Enter
Enter Material
Number
Enter Plant
Select Enter
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Overview:
A Work Center is an organizational unit where a production work step is carried out for
producing an output. The Work Center defines where and by whom an operation is to be
carried out. A cost center is assigned to each Work Center in the Work Center master
record.
Center
R = Required, O = Optional, C = Conditional
After entering, the capacity category and other formula select enter to move to detailed
Select Enter
3.4 Routing
Overview:
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A routing is a description of which operations (processing steps) have to be carried out and in
which order to produce a material (product).
In a recipe we specify,
The operations (work steps) to be carried out during production.
The Work Center used.
Based on the Work Center standard values for the execution of individual operations i.e.
the activities to be performed in the operations as a basis for scheduling, capacity
requirements and costs.
The component materials required at an operation (optional).
The required production Work Centers and tools (includes jigs and fixtures) at each
operation (optional).
The quality checks to be carried out during production (optional).
Create Routing:
Enter
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Enter
Step 1- Select the Work Center where first operation to be performed for operation number
0010. Maintain the description and base qty for the first operation detailing
If there are multiple operation performed at different Work Centers, then use same steps as
given above for all Work Centers.
Enter
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Select Enter
If material is processed in more than one Work Center then perform same procedure for
another Work Center.
Change Routing:
Select Enter
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Display Routing:
Enter
Enter Plant
Select Enter
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Routing displayed.
Overview:
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The production version determines the different production techniques that can be used to
manufacture a material.
A material may have several Bill of material (BOMs) that determine the components used in its
production. The production process can also be described in various recipes. Data on the
different methods or techniques used to produce the material is recorded in production versions
that are assigned to the material.
Production using different Work Centers (for example two different production lines)
Production of the same product using different BOMs (alternative BOMs – for example
concurrently valid old and new BOMs for a particular assembly)
Individual production quantities can be assigned to the different production versions, in order, for
example, to achieve a balanced utilization of the various alternative production lines. This can
be done by the user on an interactive basis, or automatically within the framework of the
planning run.
Select Enter
Specify Material
Enter group
Enter Routing Group Counter
version’s Upper
limit of quantity of
the material
Task List Type Task list type – O Specify the task list type
Key identify the of the material. Choose
type of the task Routing as a task list
list
Group Group – O Choose Routing group of
Key identifies the the materials
Routing
Group Counter Group Counter – O Choose Routing group
Key Identify the for the material
group counter of
Routing group
Alternative Alternative BOM- O Choose alternate BOM
BOM Key identifies the for production version
alternate BOM of
the material
BOM Usage BOM Usage – Key O BOW usage will come as
identify the BOM per selection of alternate
usage of BOM
alternative BOM
and also identifies
the area of BOM
i.e. used in
production ,
costing etc
Select Check for consistency check of production version i.e. assigned routing
and BOM will exist in specified lot size & valid date criteria
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Message will appear in screen that Task list & BOM exist.
Production version displayed through material display & production version display
list
4 DEMAND MANAGEMENT
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Overview:
Finished Pipes & Tubes, Clips, Steel Strap & Sheets will be planned with strategy 40
(Planning with final assembly).
OR
Specify Version
Enter
After select enter, new screen will come where user will enter monthly demand
quantity.
If there is any change in production plan. Production department can change the
planned quantity for the period. Demand
OR
Enter
After select enter, new screen will come where user will modify monthly
demand quantity.
OR
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Enter
After select enter, new screen will come where can check the demand .
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Overview:
Through the above functions, MRP answers the important questions, of which
material to be produced / procured, what qty and when (dates).
MRP run at plant level will select all MRP relevant material inside the plant and plan
accordingly. MRP run at plant level will be executed at the start of every month.
This will create planning proposal of all finished materials to raw materials.
MRP will generate planning proposal, which include planned orders & purchase
requisitions.
Or
Enter T code in Command field
Select Enter and system will give below message as please check input parameters
Select continue
MRP planning result will show the number new planned orders created, new
purchase requisition created etc
Enter Material to
check the MRP list
Enter Plant
Select Enter/Continue
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Stock requirement list will display the current situation of the materials. It update on each transaction
related to the material.
Select Continue
2. MRP Element:
This field denotes the ‘Demand’ or ‘Supply’ line item.
The Demand line items for a Raw material or Semi-finished products are:
a. DepReq Dependent Requirements arising from the parent materials
b. SubReq Subcontractors Requirements for goods to be supplied to Sub-
contractor (
The Supply line items for a Raw material or Semi-finished products are:
a. PldOrd Planned Order for In-House produced items like cells, electrodes etc.
b. PurReq Purchase Requisitions for items procured from vendors
c. PurOrd Purchase Orders converted from Purchase Requisitions
d. ShpgNt Shipping Notifications for Stock in transit
5. Available Qty:
This field displays the current stock in the first line.
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In each MRP element line, the system displays the forecasted stock situation for
each date, after subtracting the stock against demand line items and adding the
stock against the supply line items
6. Re-scheduling date:
Explained along with ‘Exception message’ section.
7. Exception messages:
One of the most important fields in the stock requirement list is the ‘Exception
message’ field.
Each time an MRP run is performed, the system encounters various materials,
which require the attention of an MRP controller or the ‘Purchase Personnel’.
The messages instruct that an abnormality has occurred in the date or qty
calculation and requires you to correct the line items manually.
There are 8 Exception groups, each containing a set of exceptions. Most of them
can be ignored as they will seldom occur and do have impact on date / qty
calculation.
Some of them are very important and requires the user action.
Plan Order will display the order quantity, start date, end date & master data details.
If there is change in plan order then Click on refresh icon to display the latest status of the
stock, plan order etc.
How to display the MRP results of both the parent materials and child materials?
From the ‘Stock / Requirements List as of HH:MM hrs’ screen, click on the ‘Show Overview icon’
.
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All the child material used in the parent material will appear, as shown below:
Click on each material, to display the stock requirements list for that material.
MRP run at Material level will plan materials with all MRP relevant dependent materials. MRP
run at material level will be executed whenever there is change in production plant i.e.
demand quantity. This will create planning proposal of all finished materials to raw
materials.
MRP will generate planning proposal, which include planned orders & purchase requisitions.
Enter Material
creation indicator
for the purchase
requisition
Schedule Line Schedule Line – R Enter create schedule
Indicator that line ‘3’
control the
generation of
schedule line in
MRP run
Create MRP Create MRP List – R Enter Create MRP list ‘1’.
list Indicator control This will generate the
the MRPP list for report of MRP list
all planned orders
Planning Mode Planning Mode – R Enter Planning Mode as This will
Define how the ‘3’ delete and recreate consider old
planning proposal planning data. planning data
from last run and recreate
dealt. new planning
proposal
Scheduling Scheduling – R Enter ‘2’ as scheduling Lead time
Decide the indicator. scheduling will
scheduling perform for in
procedure for house produced
planned order materials
Planning Date Planning Date – R Take current date as
Date on which planning date
planning is carried
out
Parallel Parallel Processing R Check the box of parallel
Processing – processing to increase
Key which improve the performance time of
the processing planning run
Select Enter and system will give below message as please check input parameters
Select continue
System will ask next stopping point. If we select continue as ‘plan up until stopping point’
then system will show next level.
If we select process without stopping, then MRP will plan all dependent materials then show
the result
Select Continue .
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Check the planning result in MRP list and stock requirement list.
To check the stock requirement list perform same steps as mentioned 5.1
6 CAPACITY PLANNING
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The economic use of Work Centers is an objective for many areas of a company.
The component Capacity Planning is available for this purpose. Capacity evaluation
& leveling is the part of capacity planning.
You can use capacity evaluations to analyze capacity loads in your company. You
can adjust the analyses for each user according to the planning level, planning
horizon and the area of responsibility. Available capacities and capacity
requirements can be selected according to various criteria and cumulated using any
period split you choose.
Via Transaction
Select enter
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Enter selection
criteria to
evaluate capacity.
Enter Capacity
planner & Plant
Report will
display the week
wise capacity
requirement in
work center
User can evaluate the capacity in day wise & month wise
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User can define the period as per his requirement. After deciding the periods select
continue
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To view the detailed information of each date then select day & capacity
details/period
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User can display the detailed evaluation of the process. Also user can take the
graphical view by selecting the icon.
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Via Transaction
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Select enter
Enter selection
criteria to
evaluate capacity.
Enter Capacity
planner & Plant
Capacity leveling function will show the capacity situation of planned & Production
Order. User can firm the Production Order and book the capacity by allocation the
Production Order.
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Select Execute
Capacity planning table will planned order & Production Orders in pool, which are
not firmed
To make firming the planned order or Production Order, first user needs to analyze
the capacity situation and then book the Work Centers.
For booking select the operation from pool and select dispatch.
MRP will generate the planning proposal in form of planned order & Purchase
requisition. Department person will take the planned order and convert it into
Production Order for start production process.
Planning department is responsible for Pipes & Tubes, Steel Straps, Sheets, Clips &
Skelps. Below List containing the Pipes & Tubes production Process
1. Skelps Production
2. Pipes & Tubes Production
3. Steel Straps Production
4. Clips Production
5. Sheets Production
MRP will generate the planned order only for those materials, which are part of Bill
of Materials.
All Materials are handled through batch management. In case of Skelp batch
number is equal to Coil Number and in case of finished goods batch number is
equal to production order number.
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MRP will generate the planned order for the month. Respective user will convert the
planned order into Production Order. At the time of conversion, user can split the
quantity as per production version/production line.
Enter Plant
Values
Material Material: Key R Enter the material to Specify the
identifying the know the stock material which
material requirement list is produced in
house
Plant Plant – Key R Enter the plant where to Specify the
uniquely stock requirement list plant where the
identifying the material is
plant produced
New screen will come which will display the information of planned.
Now you can convert planned order to Production Order fully and partially. If material is
produced in more than one line, then always choose partially otherwise choose fully.
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For Full Conversion choose (Convert planned order to Production Order fully)
Step 1-
After selecting Production Order icon, Production Order - creation process will start. System
will bring user to Production Order creation.
TO Check the Components to be required Production Order select below mentioned icon
Production Order - material list contains the list of materials with quantity required to
produce output material i.e. header material
It also specifies the issue location and creates reservation number for the same. Material list
will copied from BOM.
Production Order: Operation Overview shows the details of operation sequence. It will
contain the operation timing of each operation. In addition, it will contain the information of
material issue details.
Production Order number appears in stock requirement list with ‘PrcOrd’ as MRP
Element
Step 2-
In the Create Production Order screen, user can change the quantity. Then system will
convert the mentioned quantity into Production Order.
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Select Back
Now system will display the Production Order & planned Order. Because we have converted
partial quantity
This process will be used in case of immediate change in plan or new material is
coming in between the month.
Enter Plant
Select Enter
Select Enter
Select Save
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Enter Production
Order number
Select Enter
System will check the material availability and if the materials are missing system will give
message of material shortage
System will calculate the planned order cost for the Production Order.
System will check the material & capacity. If there is any shortage then system will
ask for release.
If the materials are missing then only this message will come
Message will come as Release carried out. Also check the Production Order status.
Example:
Back flush and auto goods receipt is define for all finished and semi finished
materials.
Or by Command Field
Select enter
Production Order confirmation will on operation wise
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Enter Operation
number
Enter Posting
date
Enter Shift
Select Continue
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Now Production Order will show the activity quantities and input materials
quantities as confirmation/yield quantity.
To Check and reconfirm input material quantity Select(click on) goods movement
tab
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Production Order Confirmation: Goods movements screen will show the materials
details with quantity, UOM, storage location & movement type.
In case of scrap and second quality, user need to give the material code, qty, Unit
of measure, plant, storage location, movement type.
The movement type for the scrap & second quality is 531.
case of SFG
batch number
is equal to raw
material batch
number.
Movement Movement type- C Movement type defined 261 –
Type Movement type of that material is Consumption
the material consumed or produced 101 – Goods
receipt
531 – By-
product
Production Order cancellation is needed, if user has done any wrong entry in
the system. Before cancellation user should know the Production Order,
confirmation number and counter to cancel.
Via T Code:
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Enter Production
Order Number
Select Enter
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System will ask reason for cancellation. Enter the reason and select back to
come out from cancellation screen.
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After cancellation process user need to confirm the right quantity for same
operation.
Individual technical completion can be set through the change production order
(CO02) and mass conversion can be set through the COHV.
Enter Production
Order number
Select Enter
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Status will change into TECO. Now select save to save the technical completed
status.
Select continue
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8.1 Reservation
Overview:
Material reservation is created for stock transfer or consumption to cost center for
those materials, which are kept in central store or warehouse.
In case of stock transfer, department person will raise the reservation of material
and store department will transfer the material to production storage location
By Transaction Code
Enter Plant
Enter Material
By Transaction Code
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Change quantity
By Transaction Code
Values
Reservation Reservation R Enter the reservation
Number – Key number
identifying the
reservation
Reservation displayed.
Consumables need to be issue to the cost center. Respective User will create the
reservation with the cost center movement (201) and specify the cost center.
Material will be posted to the cost center with the reference to the reservation by
store department.
Overview:
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Transfer posting can be done with respect to the reservation and without
reservation. If the responsible person for the store is different than reservation
procedure will be used and if the responsible person is same then direct transfer
posting will be performed in the system.
Select Enter
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Enter Plant
Enter Quantity
Enter Material
then no need to
enter
Plant Plant C Enter the plant If plant is
entered already
in initial screen
then no need to
enter
System will purpose the input material details then select copy .
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Select enter
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Enter reservation
Select enter.
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Specify the * in batch number then user can select the batch number and then
select adopt.
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Specify the *
Select enter
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Select Copy
Select Copy
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Overview:-
To generate the scrap through cost center, then user need to perform the following
entries. Scrap will be generating through the cost center and 531 movement type.
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Select continue
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After entering movement type, plant and document type & posting date.
Select enter
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User will specify the material, quantity, unit of measure & storage location.
Select enter
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Select save to generate the scrap stock with reference to cost center.
9 REPORTS
Select Enter
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Choose selection
option to display
respective data or
restrict the options.
Choose specific layout by choose layout option . Also user can define their own
layout.
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After taking required fields, user can save their own format by clicking save button .
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Select continue
Layout saved.
To take the graphical views then select the Colum, you want to view in graph
OR
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Select Ok and come back to header screen. In header screen user has multiple option
to view the report.
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User can take the list and define their own layout
Customized production report will show the production details on the basis of selection
criteria. User can make their own layout to get the data in day wise, month wise or in
totality.
Stock on posting date report will display the opening, receipt, consumption &
closing Stock for the period.
Via Transaction
Select Enter
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Thos report will show the opening stock, total receipt quantity, total issue quantity
& closing stock.
Enter
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Enter
selection
criteria to
display
stock
Select Execute
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Material document list will display the list all goods movement document for the
material.
Select Enter
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Enter selection
criteria to check
the material
document list
To display the
report in ALV select
detailed list icon
User make the own report variant and execute the report.
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