SAP master recipe is used to define the operations and phases which need to be carried out during a manufacturing process. Operations and phases are step by step activities which are carried out during SAP manufacturing process.
SAP has three main manufacturing methods, which are discrete manufacturing, process manufacturing and repetitive manufacturing. Master recipe is used in process manufacturing method. In discrete manufacturing, the above concept is handled through routing. When we are creating the process order, system will select the master recipe available for the material and then copy all the relevant data into the process order.
Before creating SAP master recipe, it is important to create the production version. Production version will have the bill of material (BOM) of the material which is going to be manufactured. Next, we can create the master recipe and enter the production version. Production version is a mandatory input for master recipe creation. After adding the production version to the master recipe, we can go to the production version and view the master recipe information. This system will automatically add the master recipe group number and the group counter.
There is another option of creating the master recipe without the production version. This can be achieved by creating a master recipe group. In this approach there will be no link with the material or the plant in the initial stage.
SAP Master Recipe Creation
SAP master recipe can be created by calling the transaction code C201. We can also follow the below menu path to execute the transaction:
SAP Menu -> Logistics -> Production-process -> Master data -> Master recipes -> Recipe and material list -> Create
In the selection screen, we can enter the material, plant, and the production version. Also, there is the option of enter the recipe group. Master recipe creation has been divided into several sub screens. We will discuss these next.
This screen contains the header data for the master recipe. These includes the status of the recipe, lot sizes and the default values for operations and phases.
In the master recipe we can view the BOM and the production version together. BOM is exploded in the master recipe to bring the material BOM details into the recipe. With this, process manufacturing brings a special function called material quantity calculation.
For material quantity calculations to work correctly, it is important to create the master recipe with reference to the BOM. Material quantity calculation function provides options such as calculating scrap at phase level and adding it to the production costs, change component quantities with reference to other components and change the header material quantities with reference to the components. All these functions are useful in the process manufacturing environment. We can go to the material quantity calculation by clicking the button in materials tab. In here we can define formulas. To define a formula,
- Click the select the Formula button in the menu bar.
- In the Formula definition box, enter the formula.
- We can add variables also while creating the formula.
- We can use formula operators such as +, -, *, /, DIV and MOD.
Operations and Phases
Phase is a unique object in the master recipe. This is somewhat like the operations in routing used in discrete manufacturing. Advantage of maintaining the phases is that we can enter the production process in detail at phase level. This gives better visibility into the operations which are carried out during the manufacturing process.
Process orders are confirmed at phase level and not at the operations level. The activity times such as production time, labor time and setup times are defined at phase level. Resources are assigned at operations level. Resources are like the work centers used in discrete manufacturing. Resources which are assigned at operations levels will be adopted by the phases which are below the operations level. Control key will be assigned at the phase level. In process quality inspection activities can be carried out at operations level or phase level.
When creating a phase, it is necessary to assign the operation which the phase belongs to. When we select the phase check box in the operations tab, resources which are assigned to the operation will be automatically assigned to the phases below the operation.
We can maintain relationships between phases like routing. Also, it possible to define parallel or overlapping sequences. Process instructions are assigned to the phases in the master recipe. As the name suggests, process instructions contain the specific instructions that need to be followed during the execution of the phase.
Configurations for SAP Master Recipe
SAP Master Recipe Profile
Master recipe profile can be configured by executing the transaction code OPN1 or we can follow the below IMG path:
SAP IMG -> Production planning for process industries -> Master data -> Master recipe -> Define profile with default values
Depending on the configuration of the master recipe profile, SAP provides process management options such as process instructions and XSTEPS (Execution steps).
Task list assignment to material types
Task list assignment can be configured by following the below IMG path:
SAP IMG -> Production planning for process industries -> Master data -> Master recipe -> Assign material types
Master recipe is created with reference to the task list type 2. When the process order is created, SAP will search for master recipe with task list type 2. It is important to assign the task list type 2 for all the material types which we plan to use with master recipes.
Task List Status
Task list assignment can be configured by executing the transaction code OP46 or by following the below IMG path:
SAP IMG -> Production planning for process industries -> Master data -> Master recipe -> Data for the recipe header -> Define recipe status
By default, SAP provides certain statuses such as created, released and available for costing. If required, we can define additional statuses based on the requirements.
Up to now we have analyzed SAP master recipe, its functionalities and the basic configurations required to use the master recipe. This concludes the article on SAP master recipe.
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