Question

Hector Diaz (Maria's cousin) has come up with a brillant way to use parts left over from last year's unsuccessful Spiderman Banana Bike to build a new GBI product - the Spiderman Unicycle - which will have part number UNI1001. Hector has built the necessary material master for UNI1001 in SAP and has created and entered the BOM. He has documented an assembly plan for the new product that indicates how existing work centers will be used for the new product. Maria spent two days on the phone calling all retailers and now has 100 confirmed orders. She has entered the orders in SAP. All of the parts necessary to build these 100 are already in inventory. List the SAP steps to complete the master data and build the bikes to satisfy these orders. For each step, include the module and the data needed. Number your steps. You do not need to include steps for fulfilling the orders (so no SD steps) or settling the production costs (so no CO steps).

Format for answer:

Step # Module Process Step Data needed

Answer 1

Answer:

Hector Diaz has come up with a brilliant way to use parts left over from last year's unsuccessful Spiderman Banana Bike to build a new GBI product - the Spiderman Unicycle

• Part number UNI1001.
• Material master for UNI1001 in SAP created and BOM entered.
• Assembly Plan Documented – use of existing work centers.
• Confirmed orders entered in SAP – 100 nos.
• Material Inventory available for 100 nos. of orders.

List of the SAP steps needed to complete the master data and build the bikes to satisfy these orders are as

Step	Module	Process Step	Data Needed
10	Item Creation Module	Item Number Creation in SAP	Item Number details - UNI1001, Item description – Spiderman Unicycle, Product Codes, UoM, manufactured or Brought out part. Alternate item,etc.
20	BOM Creation Module	BOM creation in the SAP	1. List of all the part numbers along with their individual unique quantity for Parent item. 2. List of work centers to be added in the BOM
30	Production Plan Module	Add Production Plan in SAP	Item Number, Item order quantity, Item child part inventory, customer shipment date, Packaging readiness, BOM readiness, Approved item for manufacturing etc.
40	Production Schedule Module	Production Schedule in SAP	Item Number, Production plan, Order Qty.
50	Job Order Creation Module	Production Schedule in SAP	Item Number , Customer name, Order qty,
60	Job Booking Module	Production Schedule in SAP	Item Number , Customer name, Order qty,
70	Inventory Back Flush	SAP Inventory Issue	Parent Item number, order Qty. The back flush operation will minus all the required inventory of child parts for 100 nos. from the SAP system and stock of 100 nos. of parent item will be created in SAP by back flush operation.

Thus with the above SAP steps, the 100 order quantity of Spiderman Unicycle has been build in the system with the part number - UNI1001.