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SAP Best Practices for Semiconductor and Photovoltaic Companies V1.604 (CN) SAP Best Practices General Information SAP Best Practices for Semiconductor and Photovoltaic Companies was developed for small and midsize companies to implement a solution quickly and easily. With a focus on the primary manufacturing business processes this package gives you built-in support for the best business practices in the industry. Functionalities The SAP Best Practices for Semiconductor and Photovoltaic Companies V1.604 package supports your business in the following areas : Production planning and control Materials management Sales and distribution Logistics, Batch management with batch derivation and Serial number Management , and quality management Accounting Controlling Forms and reporting SAP BP for Semiconductor and Photovoltaic Companies V1.604 : Solution Scope (1 of 2) Product Development Procurement & Consumption of Consigned Inventory Planning and Processing of Semifinished Goods Sales Order Processing with Customer Down Payment Internal Product Development Internal Procurement: Cross-Company Stock Transfer Co-Product Manufacturing Sales: Period End Closing Operations Tool Production Credit Memo Processing Engineer-to-Order (ETO) – Project Assembly Foreign Trade Export Processing Demand and Supply Planning Advanced Batch Management Logistics Planning Purchasing with JIT Delivery Schedules Quarterly Plan - Sales Quantity Forecast with CO-PA Outsourced Manufacturing Material Substitution in MRP using Discontinued Part Control Strategic Sourcing & Procurement Quotation for Procurement Subcontracting with Chargebal Component Subcontracting Manufacturing with Down Binning and Batch Derivation Batch Management with Enhanced Characteristics Customer Consignment Processing Make-to-Stock Production with Order Split Manufacturing with Production Order Split and Batch Derivation Production Subcontracting with CoProducts and Batch Derivation Solar Cell Retesting Rework Processing (Work in Process) with Batch Management Fulfillment and Logistics Quotation, Contract and Order Management Consumable Purchasing Procurement without QM Stock Handling: Scrap and Blocked Stock Procurement Contract Stock Transfer with Delivery Stock Transfer without Delivery Make-to-Stock Production – Discrete Industry Make-to-Order Production with Variant Configuration Sales Processing Using Third Party (w. Shipping Notification) Credit Management Returnables Processing Rebate Processing: Free Goods Batch Recall Sales Order Processing with Collective Billing Cross-Company Sales Order Processing Handling Unit Management (HUM) for Production Order Sales with Scheduling Agreement Engineer-to-Order (ETO) – Quotation Processing Cash Sales Orders Return to Vendor Make-to-Order Production w/o Variant Configuration Sales Order Processing – Sale from Stock Physical Inventory/ Inventory Count and Adjustment Repetitive Manufacturing Free of Charge Delivery Shipping and Receiving with Warehouse Management Production Subcontracting (External Processing) Sales Quotation Batch Recall with Batch Identification Sales Order Processing for Prospect Sales Processing with Variant Pricing Configuration External Procurement of Third-party resources External Procurement Services Batch Management Serial Number Management Quality Management for Procurement with Vendor Evaluation Subcontracting Rework Processing (Stock-Manufactured Material) Rework Processing (Work-in-Process) Quality Management in Discrete Manufacturing Repetitive Manufacturing with Kanban Supply in Production Sales Processing using Third Party (without Shipping Notification) Sales of Nonstock Item with Order Specific Procurement Debit Memo Processing Lean Warehouse Management Black = Baseline Scenarios Red = Discrete Manufacturing Scenarios Blue = Semiconductor & Photovoltaic Scenarios SAP BP for Semiconductor and Photovoltaic Companies V1.604 : Solution Scope (2 of 2) Warranty and Returns Returns and Complaints Period End Closing Service Orders Internal Maintenance Spot Consulting with Fix Priced Billing Sales Order with Fixed Price and T&M Billing Project with Fixed Price and T&M Billing Internal Project Asset Acquisition through Direct Capitalization Activate Document Splitting Cost of Sales Accounting Segment Reporting Time Recording Corporate Services Travel Management Management Accounting Service Contract with Periodic Billing Internal Order R&D Planning Service with Fixed Price Billing Internal Order for Marketing and Other Overhead Planning Sales Returns with Quality Management (QM) Human Capital Management Document Splitting for Semiconductor & Photovoltaic Companies General Cost Center Planning Depot Repair Actual Costing with Material Ledger Activate Document Splitting for Discrete Manufacturing Service with Time & Material Based Billing Sales of Planned Services Variance Calculation and WIP reporting SAP ERP Reports for Accounting SAP ERP Reports for Logistics Overhead Cost Accounting – Actual Internal Order R&D Actual Internal Order for Marketing and Other Overhead Actual Advanced Customer Returns Management Revenue Planning Financial Accounting SOP through Long Term Planning Transfer to LIS/PIS/Capacity General Ledger Purchased Material Price Planning Accounts Receivable Manufacturing Cost Center Planning Accounts Payable Standard Cost Calculation Period End Closing Financial Accounting Period End Closing “General” Plant Cash Management Inventory Valuation for Year End Closing Asset Accounting Reference and Simulation Costing Asset Acquisition for Constructed Assets (Investment Orders) Period End Closing Projects Period End Closing Activities Black = Baseline Scenarios Red = Discrete Manufacturing Scenarios Blue = Semiconductor & Photovoltaic Scenarios Industry-Specific Scenarios New Scenarios Enhanced Scenarios SAP Best Practices for Semiconductor and Photovoltaic Companies V1.604 (CN) provides the following industry-specific scenarios: 450: Manufacturing with Production Order Split and Batch Derivation 451: Subcontracting Manufacturing with Down Binning and Batch Derivation 452: Production Subcontracting with Co-Products and Batch Derivation 453: Batch Management with Enhanced Characteristics 454: Batch Recall with Batch Identification 455: Rework Processing (Work in Process) with Batch Management 456: Document Splitting for Semiconductor & Photovoltaic Companies 457: Variance Calculation and WIP reporting 458: Sales Processing with Variant Pricing Configuration 459: Material Substitution in MRP using Discontinued Part Control 460: Solar Cell Retesting 462: Actual Costing with Material Ledger Manufacturing with Production Order Split and Batch Derivation (450) Purpose and Benefits: Purpose To model the complete processing of manufacturing, costing, and lot tracking for semiconductor and photovoltaic internal manufacturing. This scenario describes a business process, which is typical for semiconductor and photovoltaic manufacturing including lot-size oriented production. The production scenario produces a finished good and procures all dependent components in maketo-stock production (MTS). Work-in-Process (WIP) Batch is used to record the current properties of the material on a quantity basis. Furthermore the WIP batch ensures that end-to-end batch tracing is possible. This scenario is supported by the main cost object controlling functions required, such as preliminary costing and period-end closing. Benefits Production triggered by a production plan Serial number and batch management included WIP Batch Key process flows covered Creating Planned Independent Requirements Material Requirements Planning at Plant Level In-House Production with Batch Derivation (Semi-finished product) In-House final assembly with Co-Products and Batch Derivation (Finished product) Production Order Splitting Confirming Assembly Activities WIP Batch GR Batch Subcontracting Manufacturing with Down Binning and Batch Derivation (451) Purpose and Benefits: Purpose Model and illustrate semiconductor manufacturing at the contract manufacturer Benefits Sub contract manufacturing for semiconductor industries Key process flows covered Run material requirements planning for semiconductor devices and die Create subcontract purchase orders for finished devices Manage die and components in lots (batches) Issue die and components to sub-contract purchase order Update batch characteristics In-House Production with Batch Derivation (Final Testing) Down Bin material Production Subcontracting with Co-Products and Batch Derivation (452) Purpose and Benefits: Purpose During the Manufacturing process, when a "Planned Order" for Production is converted to a "Production Order", the system will check to see if there are any routing/work-center operations which require external processing. External processing is when you have individual production steps, that are operations or sub-operations, which are performed outside of your company by a vendor. This type of processing is particularly important for subcontracting. It can also provide a company with a feasible alternative to in-house processing, if capacity bottlenecks occur. Benefits An Info Record can specify that a certain operation of the production order is executed by an external subcontractor on a regular basis In the case of capacity bottlenecks, the assembly procedure of the finished product can be assigned to a subcontractor Key process flows covered Execute MRP to generate the production orders and subsequent subcontract purchase requisitions Convert Subcontract Purchase Requisition to Subcontract Purchase Order for External Processing Posting Goods Issue and posting In-time Consumption of Components Perform Goods Receipt of Products for “Subcontract” Purchase Order Confirm the final processing step within the production order Update the production order and the appropriate Co-product quantities Perform Goods Receipt of Production order Enter Invoice Periodic Payment Batch Management with Enhanced Characteristics (453) Purpose and Benefits: Purpose If materials are handled in batches it will be necessary to change batch master data or to find out where a batch is used; for example, to perform a batch recall or report to government. Benefits To change batch master data To find out where a batch was used, e.g. to perform a batch recall or government report To find out where a batch is used, e.g. in which stocks or inspection lots or material documents To have a single point of batch maintenance Key process flows covered Maintain batch master record with characteristic values Batch information cockpit Batch Recall with batch identification (454) Purpose and Benefits: Purpose A defect batch is identified and must be recalled from customers and prospects who have received the batch. Benefits Integrated follow-up process to the former delivered batch Return stock managed separately from the rest of your stock Key process flows covered Identify all finished goods batches affected by defect batch Identification of customers who received the defect batch Creation of direct mailing to customer Preparing follow-up process for the return of the batch Receiving of returned batch into return stock Decision of further usage of the returned stock Creation of credit memo for customer Rework Processing (Work in Process) with Batch Management (455) Purpose and Benefits: Purpose Processing of defective material within a production order. Benefits Scrap at defined operation automatically trigger rework process. After rework, additional activity and material consumption can be confirmed. Fully integrated in the production process Maintains batch history Key process flows covered Confirming Production Activities Confirm Scrap defective material Confirm Rework Operation Continue Shopfloor-Activities Goods Receipt Document Splitting for Semiconductor & Photovoltaic Companies (456) Purpose and Benefits: Purpose The Activate Document Splitting is provided with the new General Ledger Accounting Documents are enhanced with additional account assignment objects, or additional postings are done which split the original postings into lines referring to the account assignment objects Account assignment objects can be defined according to selected dimensions. In SAP Best Practices the dimensions are profit centers and segments Benefits The postings are done in real time (online) It is possible to draw up complete financial statements for the selected dimensions at any time (segment reporting) Key process flows covered Find or create a document whose G / L Account with Different Segments Check and display assignment profit center and segment Variance Calculation and WIP reporting (457) Purpose and Benefits: Purpose This scenario demonstrates how to generate reports that identify production variances and the value of WIP. Benefits The cost variances between planned and actual costs can be viewed at the end of each month. The value of WIP at the plant and production order level can be easily identified at the end of each month. Key process flows covered How to execute the production variance report How to execute the WIP report Sales Processing with Variant Pricing Configuration (458) Purpose and Benefits: Purpose This scenario is designed for foundry automatic pricing procedure. We assume that the semiconductor foundry delivery finished wafer to fable companies directly, not die-base. Benefits The quotation price is determined on the basis of the manufacturing costs of the quoted product via variant conditions Key process flows covered Creation of the quotation Deriving Sales Order from Quotation Material Requirements Planning for MTO Sales Order Converting Planned Order to Production Order Evaluation of the Stock/Requirement List Manufacturing Steps (Make-to-Order) Creating Outbound Delivery Picking and Goods Issue Creating Billing Document Material Substitution in MRP using Discontinued Part Control (459) Purpose and Benefits: Purpose This scenario describes the process of the raw material substitution functionality in MRP for the photovoltaic industry. Benefits Developed new material to replace the old one to finally improve the product. Assuming material A and B are mutual substitutions, production planner manually decided which raw material is used during production. An alternative item group is used to group together alternative items in a BOM. Assuming discontinued material C has been replaced by material D after the specific period. Used discontinuation functionality is transfer dependent requirements of a component to the follow-up materials, if the requirements are no longer covered by stock. Key process flows covered Create Planned Independent Requirements Change the BOM to decide which raw material is used during production Change the Material Master to automatic substitution for discontinued material Material Requirements Planning at Plant Level Evaluation of the Stock/Requirement List Create Production Order Solar Cell Retesting (460) Purpose and Benefits: Purpose After solar cell have been produced and stored in the warehouse for a period of time, there is a possibility that the conversion efficiency of some solar cells will change for some unstable reason. So before using solar cells to assemble to solar module in plant or sell these solar cells to customer directly, the solar cells should be re-tested and sorted again according to their new conversion efficiency. This scenario describes the solar cell retesting process. Benefits For solar cells which are Efficiency, you have 3 options: Option 1: No Attribute Change for Retested Solar Cells Option 2: Attribute Change For All Retested Solar Cells Option 3: Attribute Change For Partial Retested Solar Cells For solar cells which are No-Efficiency Defects Recording Usage Decision to Scrap No-efficiency Solar Cells Key process flows covered Create Stock Transfer Request Quality Inspection Recording Results Goods are Efficiency • Option 1: No Attribute Change for Retested Solar Cells • Option 2: Attribute Change For All Retested Solar Cells • Option 3: Attribute Change For Partial Retested Solar Cells • Maintain Batch Master Record Goods are No-Efficiency • Defects Recording • Usage Decision to Scrap No-efficiency Solar Cells Actual Costing with Material Ledger (462) Purpose and Benefits: Purpose This scenario describes the process of calculating the actual cost of materials and separating the differences between standard cost and actual cost into cost of sales and stock value using material ledger settlement function. Benefits System calculates the actual cost of materials with material ledger CO-PA data is revaluated with actual cost Key process flows covered Creating Costing Run Determining Material Prices Consumption Revaluation Closing Postings Confirming Costing Result CO-PA Periodic Revaluation Marking Material Price Releasing Material Price Legend <Function> Symbol Description Usage Comments Band: Identifies a user role, such as Accounts Payable Clerk or Sales Representative. This band can also identify an organization unit or group, rather than a specific role. Role band contains tasks common to that role. Symbol Diagram Connection The other process flow symbols in this table go into these rows. You have as many rows as required to cover all of the roles in the scenario. Hardcopy / Document External to SAP External Events: Contains events that start or end the scenario, or influence the course of events in the scenario. Business Activity / Event Flow line (solid): Line indicates the normal sequence of steps and direction of flow in the scenario. Flow line (dashed): Line indicates flow to infrequentlyused or conditional tasks in a scenario. Line can also lead to documents involved in the process flow. Connects two tasks in a scenario process or a non-step event Business Activity / Event: Identifies an action that either leads into or out of the scenario, or an outside Process that happens during the scenario Does not correspond to a task step in the document Unit Process: Identifies a task that is covered in a step-by-step manner in the scenario Corresponds to a task step in the document SubProcess Reference Proces s Decisio n Usage Comments To next / From last Diagram: Leads to the next / previous page of the Diagram Flow chart continues on the next / previous page Hardcopy / Document: Identifies a printed document, report, or form Does not correspond to a task step in a document; instead, it is used to reflect a document generated by a task step; this shape does not have any outgoing flow lines Financial Actuals: Indicates a financial posting document Does not correspond to a task step in a document; instead, it is used to reflect a document generated by a task step; this shape does not have any outgoing flow lines Budget Planning: Indicates a budget planning document Does not correspond to a task step in a document; instead, it is used to reflect a document generated by a task step; this shape does not have any outgoing flow lines Manual Process: Covers a task that is manually done Does not generally correspond to a task step in a document; instead, it is used to reflect a task that is manually performed, such as unloading a truck in the warehouse, which affects the process flow. Existing Version / Data: This block covers data that feeds in from an external process Does not generally correspond to a task step in a document; instead, this shape reflects data coming from an external source; this step does not have any incoming flow lines System Pass / Fail Decision: This block covers an automatic decision made by the software Does not generally correspond to a task step in the document; instead it is used to reflect an automatic decision by the system that is made after a step has been executed. Financial Actuals Budget Planning Manual Proces s Unit Process Process Reference Description Process Reference: If the scenario references another scenario in total, put the scenario number and name here. Sub-Process Reference: If the scenario references another scenario in part, put the scenario number, name, and the step numbers from that scenario here Process Decision: Identifies a decision / branching point, signifying a choice to be made by the end user. Lines represent different choices emerging from different parts of the diamond. Corresponds to a task step in the document Corresponds to a task step in the document Does not usually correspond to a task step in the document; Reflects a choice to be made after step execution Existing Version / Data System Pass/F ail Decisio n