Discrete Manufacturing ERP (PP) Training Course

Discrete Manufacturing ERP (PP) Training Course

Introduction

Discrete Manufacturing ERP (PP) Training Course is meticulously designed to equip professionals with deep, practical expertise in the Discrete Manufacturing processes within an Enterprise Resource Planning (ERP) system's Production Planning (PP) module, such as SAP PP or equivalent. Discrete Manufacturing which focuses on producing distinct, individually countable products demands precision in Bill of Materials (BOM) management, Routing, and Shop Floor Control. This training goes beyond theoretical knowledge, focusing on hands-on Configuration and Customization to address real-world business challenges like managing Make-to-Order (MTO) and Assemble-to-Order (ATO) environments. By mastering Material Requirements Planning (MRP) and Capacity Planning, participants will learn to optimize resource utilization, ensure On-Time Delivery, and significantly improve the overall Supply Chain visibility.

The modern manufacturing landscape is undergoing a rapid Digital Transformation, driven by Industry 4.0 technologies. Proficiency in the ERP PP module is now a critical skill for maintaining a competitive edge. This course will bridge the gap between business requirements and system functionality, emphasizing crucial integration points with Materials Management (MM), Sales and Distribution (SD), and Financial Accounting (FICO). Trainees will gain the ability to analyze Production Variances, implement Advanced Planning and Scheduling (APS) techniques, and leverage Real-Time Data for superior decision-making, ultimately driving Operational Efficiency and measurable cost reduction in complex discrete environments.

Course Duration

5 days

Course Objectives

·         Master end-to-end Discrete Manufacturing life cycle in the ERP PP environment.

·         Configure and manage robust Master Data including BOM Version Control and complex Routings.

·         Execute advanced Material Requirements Planning (MRP) runs for optimized inventory.

·         Implement Demand Management strategies for Make-to-Order (MTO) and Make-to-Stock

·         Perform effective Capacity Planning and Capacity Leveling for resource optimization.

·         Manage the complete Production Order cycle, including creation, release, and Settlement.

·         Utilize Shop Floor Control to ensure Real-Time Visibility of Work-in-Progress

·         Implement Automated Goods Movements like Backflushing for streamlined execution.

·         Analyze and resolve Production Variances and calculate accurate Job Costing.

·         Understand and leverage PP module integration with MM, SD, FICO, and QM modules.

·         Apply principles of Lean Manufacturing and Just-in-Time (JIT) within the ERP system.

·         Explore S/4HANA innovations like Embedded Analytics and Fiori Apps for PP.

·         Troubleshoot common system issues related to Production Scheduling and Batch Management.

Target Audience

1. ERP/SAP PP Consultants
2. Production Planners and Schedulers
3. Manufacturing Managers and Supervisors
4. Supply Chain Analysts
5. Materials Management (MM) Specialists
6. Business Process Owners in Manufacturing
7. IT System Implementers and Support Staff
8. Cost Accountants involved in Production Costing

Course Modules

Module 1: Foundations & Master Data Excellence

• ERP Landscape and PP integration with other core modules
• Detailed configuration of Material Master settings for Discrete Production.
• Creation and Maintenance of multi-level Bills of Material.
• Defining Work Centers and complex Routings
• Configuring Production Versions and understanding their role.
• Case Study: Optimizing the BOM structure for an Automotive Component Manufacturer to reduce data entry errors and simplify engineering changes.

Module 2: Demand & Sales Integration

• Understanding different Planning Strategies
• Creation and Management of Planned Independent Requirements (PIRs).
• Detailed overview of Sales and Operations Planning (SOP).
• Executing Availability Check (ATP) logic against planning.
• Impact of Sales Orders on the Demand Program.
• Case Study: Implementing a Make-to-Order strategy for a High-Tech Electronics firm, linking sales demand directly to production planning.

Module 3: Material Requirements Planning (MRP)

• In-depth explanation of the MRP Run process and logic
• Configuring Lot-Sizing Procedures and MRP Areas.
• Processing and converting Planned Orders into Production Orders.
• Evaluating the MRP List and Stock/Requirements List for exception handling.
• Introduction to Master Production Scheduling (MPS).
• Case Study: Streamlining the MRP process for a Medical Device company to eliminate material stockouts and reduce excess safety stock.

Module 4: Capacity & Shop Floor Execution

• Defining and calculating Available Capacity at the Work Center.
• Performing Capacity Requirements Planning.
• Techniques for Capacity Leveling and overload resolution.
• Overview of Shop Floor Control and the Production Order life cycle.
• Configuring Scheduling Parameters and lead time offsetting.
• Case Study: Resolving a production bottleneck at a heavy machinery manufacturer using advanced capacity leveling tools and Work Center optimization.

Module 5: Production Order Management

• Customizing Production Order Types and dependent parameters.
• Order Creation, Release, and Printing of Shop Paper.
• Performing Material Staging and Goods Issue to the order.
• Processing Order Confirmation and Scrap recording.
• Configuring and executing Automatic Goods Receipt.
• Case Study: Implementing mobile-based Order Confirmation on the shop floor for a fast-moving consumer goods manufacturer, improving data accuracy.

Module 6: Advanced Execution & Integration

• Configuration and use of Backflushing for automatic material consumption.
• Batch Management setup for product traceability and shelf life.
• Processing Rework Orders and handling production exceptions.
• Deep-dive into Production Order Settlement and Variance Calculation
• Understanding the role of Quality Management integration in-process inspection.
• Case Study: Establishing full Product Traceability for an Aerospace part manufacturer using Batch Management and detailed confirmation processes.

Module 7: Reporting, Analytics & Improvement

• Utilizing standard PP reports for production analysis.
• Leveraging Business Intelligence (BI) and Embedded Analytics for KPI tracking.
• Analyzing Planned vs. Actual Costs on Production Orders.
• Measuring and improving key metrics.
• Introduction to Lean Principles and continuous process improvement in PP.
• Case Study: Developing a custom Fiori Dashboard for a plant manager to track daily production status and identify cost overruns in real-time.

Module 8: S/4HANA & Digital Manufacturing Focus

• Key differences and migration aspects from legacy ERP to S/4HANA PP.
• Introduction to Advanced Planning and Scheduling and PP/DS.
• Exploring the integration with Manufacturing Execution Systems.
• Overview of IoT and sensor data impact on shop floor reporting.
• Role of Cloud ERP and future trends in manufacturing planning.
• Case Study: Simulating a future scenario where IoT-enabled machines auto-confirm operations and trigger material reorder points instantly.

Training Methodology

This course employs a participatory and hands-on approach to ensure practical learning, including:

• Interactive lectures and presentations.
• Group discussions and brainstorming sessions.
• Hands-on exercises using real-world datasets.
• Role-playing and scenario-based simulations.
• Analysis of case studies to bridge theory and practice.
• Peer-to-peer learning and networking.
• Expert-led Q&A sessions.
• Continuous feedback and personalized guidance.

Register as a group from 3 participants for a Discount

Send us an email: info@datastatresearch.org or call +254724527104 

Certification

Upon successful completion of this training, participants will be issued with a globally- recognized certificate.

Tailor-Made Course

 We also offer tailor-made courses based on your needs.

Key Notes

a. The participant must be conversant with English.

b. Upon completion of training the participant will be issued with an Authorized Training Certificate

c. Course duration is flexible and the contents can be modified to fit any number of days.

d. The course fee includes facilitation training materials, 2 coffee breaks, buffet lunch and A Certificate upon successful completion of Training.

e. One-year post-training support Consultation and Coaching provided after the course.

f. Payment should be done at least a week before commence of the training, to DATASTAT CONSULTANCY LTD account, as indicated in the invoice so as to enable us prepare better for you.