• No BOM is effective: On the explosion date and in the given area of validity, For the given effectivity parameters
• The BOM has a deletion indicator.
• The BOM is a multiple BOM, and has no alternative that matches the lot size for your required quantity.
• No BOM matches the selection criteria of the BOM application you selected.

This is possible in the following situations, for example:

• The application does not take all BOM usages into account. 

  For example, the application only takes BOMs that are relevant to production into account, so a BOM that is relevant to sales and distribution is not exploded.

• The application selects a specific alternative on the explosion date you require. The material master record supports alternative determination by Explosion date.

  If the specified alternative is not valid on the explosion date, the BOM is not exploded.

• The application takes production versions in the material master record into account, but no production version has a BOM that is valid on the explosion date you require.

  The material master record supports alternative determination by Production version. The SAP system only explodes the BOM defined for the production version that matches the alternative and/or usage entered on the explosion date required.

• The application only takes BOMs with certain status indicators into account. 

  For example, the application for MRP only explodes BOMs that have at least the status Explosion for MRP.

Further checks:

- Do the proper Scheduling in Routing (Backward/forward). In md61 give the requirement in next month.check your in-house production, planned delivery time in md02 give MRP Control parameter Rexplode BOM and Routing.

- Check BOM explosion data in MRP4 view of material master view ( Individual/Coll data).

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For example, you need to set item relevant to production flag for each material in BOM by mass change function in CS02 transaction.

If the materials in the BOM has already been flagged this indicator. When you select mass change function, the item relevant to production indicator still not be flagged. Therefore, there is no log records in change history document.

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Standard value key is the key which defining and giving a dimension such as time or area, to one of up to six standard values.

SAP system uses standard values as parameters with origin “standard value” in formulas to calculate execution time, capacity requirements and costs.

The standard value key is used to assign a parameter ID to standard values. This parameter ID identifies the standard value in a formula. The parameter ID can be used to determine the key word for a standard value, such as setup, machine or labor.

The key words identify standard values in the operations of a task list. You have to assign values to the standard values in the task list.

Define Standard Value Key

To define standard value keys. The standard value key determines the meaning of the six standard values in the operation. The SAP System assigns a parameter ID to the standard values of the operation and the work in network activities.

The parameter ID in turn determines:

• the key word displayed for the standard value on the screen, for example, setup, machine, labor, teardown etc.
• the dimension (for example, time, quantity, volume) of the standard value

At the same time, the parameter IDs are the names used for the standard values in formulas for the calculation of

• execution time
• capacity requirements
• costs

A parameter which is to be used in a standard value key must have the origin “2″.

If capacity leveling is used, SAP recommends that you always enter the parameter key for the setup standard values in the same position (for example, in the first column) in all standard value keys.

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Material Groups in SAP system

With material groups you group materials with the same attributes or purpose.

Material groups in SAP system can be used to:

• Limit the scope of analyses
• Systematically search for material master records via matchcodes

In the component Sales and Distribution (SD), you can assign material groups to divisions.

In OMSF transaction, define Material Group in SAP system

1. Define your material groups.
2. Assign each material to a material group.

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The item status covers a range of indicators that can be entered for BOM items, relevant to engineering, relevant to production, relevant to costing, and so on, for example.

These item status indicators control:

• Processing of the BOM in related application areas. The indicators define whether further processing is required, allowed, or not allowed. If processing in an application area is supported, you can maintain application-specific data for the items. For example, only items that are relevant to production are copied to a production order.
• The selection of items for BOM explosion

Item Status Indicators

You can define indicators as optional fields for a BOM usage. This means that you can set these indicators for one item in a BOM and not for another item.

In Customizing for Production, application areas are defined for which BOM items are relevant by using the following indicators:

• Item relevant to production – can be maintained
• Item relevant to engineering – must be maintained
• Item relevant to plant maintenance – cannot be maintained
• Item relevant to sales and distribution – cannot be maintained
• Item relevant to costing
• Spare part – can be maintained

Before you can enter PM structure elements and items relevant to plant maintenance in functional location BOMs and equipment BOMs, you need to choose a BOM usage that supports plant maintenance items.

Each area (for example, production or design) maintains a separate BOM with a separate usage. If you create several BOMs for one material with different usages, the system saves each BOM usage under a separate internal BOM number.
Authorizations for BOMs are defined per BOM usage.

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• design BOM
• production BOM
• costing BOM

The design BOM includes all the components of the product and their technical data from the design point of view. This BOM is generally not linked to any order.

The production BOM includes all the items required from the production and assembly point of view. To assemble a product, you only require items that are relevant to production, which contain process data.

The costing BOM describes the product structure and is used to automatically determine the costs of the materials required for a product. Items that are not relevant to costing are not included in the costing BOM.

Each area (for example, production) creates its own BOM that contains application-specific data, instead of using one BOM for the entire company. Each area can target the BOM explosion to find only the data that is relevant. The data shown in a BOM explosion also depends on how the BOM application is defined. For example, a BOM application can define priorities for BOM usages.

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The standard SAP system allows you to maintain individual BOMs for any area of your company. These BOMs are maintained independently of each other and are assigned different internal BOM numbers.

In this way, each area is only dealing with the specific data it requires.

In Customizing for Production, define individual BOM usages for the different areas within your company by choosing

Basic data > Bill of Material > General data > BOM usage > Define BOM usages

BOM usages can be defined for the following scenarios:

• You maintain separate BOMs for different areas within your company, such as design or production.
• You create just one BOM for all areas within your company.

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If you want to use company-specific criteria (instead of dates) to determine when changes are effective, parameters to define effectivity can be used then.

The standard SAP System provides 2 effectivity types

• time period
• serial number range

For example, effectivity type “time period” lets you react quickly to seasonal changes in the market by defining a change to a product (such as color or extras) for a specific time period.

If you want to use other, company-specific effectivity conditions, you can define your own effectivity types in the SAP System.

Before parameter effectivity can be used to define when changes to BOMs are effective, you must define the following settings in

Customizing for Logistics General > Engineering change management

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• You can allocate a BOM created in a specific plant (such as 0001) to additional plants (such as 0002 and 0003) or to the entire group (blank).
• You can allocate a group BOM to individual plants.

These related BOMs are identified by a common internal BOM number in the standard SAP system. This internal BOM number is displayed on all screens for plant allocations.

Before you can allocate the same BOM to a material in different plants, the following must apply:

• The material whose BOM you want to allocate to an additional plant must have a material master record in the new plant. All material items in the BOM must have valid material master records in the new plant in SAP.  If the BOM is only relevant to plant maintenance, you can allocate the BOM to plants where no plant data exists.
• If the unit of issue is maintained in a BOM item, this unit must be the same in all plants.
• If the BOM contains a non-stock item that has a cost element, the SAP system checks the account. If the cost element is for primary costs, the SAP system checks whether the G/L account exists for the company code. The SAP system uses the valuation area and the plant to which the BOM is allocated to determine the company code. Secondary costs are only maintained in cost accounting.

If you want to allocate the BOM for a material to a plant where the material already has a multiple BOM (identified by the same internal BOM number), you can only allocate one alternative from this BOM group to the material in this plant.

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Material BOMs can be valid on different organizational levels:

A material BOM can be used to manage data that applies directly to production. This is why the area of validity is the plant. The plant is the location where all necessary work-scheduling procedures are organized, such as MRP and creating routings.

In this case, BOM can be created with a plant-specific.

However, a group BOM can be created without reference to a plant. For example, a designer maintains a group BOM during the design phase of a product, then the BOM is allocated to one or more plants for production purposes.

If you create a material BOM without reference to a plant, the BOM is valid throughout your company. To do this, you leave the Plant field blank. The SAP system checks whether material masters exist. There are no SAP system checks for plant data.

Plant-Specific Material BOM

If you create a material BOM with reference to a plant, the SAP system makes a number of checks. A material master record with plant data for the relevant plant must exist for the BOM header material. When you enter items, the SAP system checks whether plant data exists for the material components

The checks for creating a material item in a plant-specific BOM

First, the SAP system checks whether the material master record exists. Then the SAP system checks the plant-specific material data. If these checks are successful, the SAP system accepts the material in the material BOM.

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A bill of material that can be create for a material is known as a material BOM in the SAP System.

To create a material master in the SAP System, you can use the following functions:

Material > Create > Immediately

For this material, the SAP system creates a material master immediately, so that you can also create a BOM for it.
 

Material > Create > Schedule

For this material, the SAP system only generates a change document. This is why BOM cannot be created for the material at first.

Only when you activate the scheduled material does the SAP system create a material master record. Then you can create a BOM for it.

The material master record contains descriptive data such as the size, dimension, and weight of the material, and control data such as the material type and the industry sector. In addition to this user-maintained data, the material master record also contains data that is updated by the system, such as stocks.

Material BOMs are mainly used to represent the structure of products manufactured within your company. You can enter both materials and documents as components of this BOM. A document info record must exist in your SAP System for each document you enter.

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Before you can create a BOM for the component parts of an object, the object must have a valid master record in SAP system.

The following shows the objects for which BOMs can be created.

• Material Master Record –> Material BOM
• Equipment Master Record –> Equipment BOM
• Document Info Record –> Document BOM

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You can break down large and complex product structures into a number of related units. Each unit can be represented by a BOM, referred to in this documentation as a single-level BOM.

A single-level BOM describes one or more assemblies by means of component quantities. In the following, the term single-level BOM will be shortened to BOM.

In practice, a single-level BOM is often a collection of standardized assemblies. A single-level BOM can be either a complete machine or an individual part.

Single-level BOMs can be used to define one-time solutions for recurring tasks. Once you have defined your solution in the form of a single level BOM, it can be used whenever you need it and combine it with other BOMs as required.

Assemblies

Assembly is a group of semi-finished products or parts that are assembled together and form either a finished product or a component of a finished product.

An assembly is identified by a material number and generally functions as a single unit.

The term “assembly” comes from material BOM applications. In document structures (in document management applications) this term refers to a coherent grouping of a quantity of documents and texts.

Phantom Assemblies

A phantom assembly is a logical (rather than functional) grouping of materials.

• From the design point of view, these materials are grouped together to form an assembly. The components of a phantom assembly are grouped together to be built into the assembly on the next level up the product structure.
• From the production point of view, these materials are not actually assembled to form a physical unit.

the special procurement key phantom assembly can be defined in the material requirements planning (MRP) data of the material master record for a material.

Dependent requirements for the superior assembly are passed directly down to the components of the phantom assembly, skipping the phantom assembly. Planned orders and purchase requisitions are also produced only for the components of the phantom assembly.

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• A design department (working with CAD) can base its work on bills of material. BOMs can be created in the SAP system from CAD program, via the SAP-CAD interface.
• Material requirements planning (MRP) department explodes bills of material) on a certain date to calculate cost-effective order quantities for materials.
• A work scheduling department uses bills of material as a basis for operation planning and production control.
• A production order management department, uses bills of material to plan the provision of materials.

The data stored in BOMs is also used in other activities in a company such as:

· Sales orders: As an aid to data entry. You can also create and maintain a BOM specifically for a sales order (variant configuration).

· Reservation and goods issue: As an aid to data entry

· Product costing: To calculate the costs of materials required for a specific product

This simultaneous use of BOM data in different areas of a company illustrates the advantage of a system based on integrated application components. Links between application components facilitate continuous data exchange between different application areas, giving all users access to the latest data at all times.

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BOMs (Bills of Material in Production Planning) is a 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.

BOMs are used in their different forms in various situations where a finished product is assembled from several component parts or materials. Depending on the industry sector, they can also be called recipes or lists of ingredients and so on.

BOMs in Production Planning (SAP PP) contain important basic data for numerous areas of a company, for example:

· MRP

· Material provisions for production

· Product costing

· Plant maintenance

The following BOMs can be created in the SAP system:

· Material BOMs

· Equipment BOMs

· Functional location BOMs

· Document structures

· Order BOM

· Work breakdown structure (WBS) BOM

Selection Criteria – Selection is necessary if you plan production in the system or if you want to maintain BOMs for technical objects from the area plant maintenance. If very large documents about BOMs are to be cumulated in the document management system (DMS), you also have to select these components

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