Transcript SAP Best Practices for Semiconductor and Photovoltaic Companies

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
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Materials management
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Sales and distribution
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Logistics, Batch management with batch derivation and Serial number Management ,
and quality management
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Accounting
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Controlling
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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:
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450: Manufacturing with Production Order Split and Batch Derivation
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451: Subcontracting Manufacturing with Down Binning and Batch Derivation
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452: Production Subcontracting with Co-Products and Batch Derivation
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453: Batch Management with Enhanced Characteristics
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454: Batch Recall with Batch Identification
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455: Rework Processing (Work in Process) with Batch Management
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456: Document Splitting for Semiconductor & Photovoltaic Companies
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457: Variance Calculation and WIP reporting
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458: Sales Processing with Variant Pricing Configuration
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459: Material Substitution in MRP using Discontinued Part Control
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460: Solar Cell Retesting
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462: Actual Costing with Material Ledger
Manufacturing with Production Order Split and
Batch Derivation (450)
Purpose and Benefits:
Purpose
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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
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Production triggered by a production plan
Serial number and batch management included
WIP Batch
Key process flows covered
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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
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Model and illustrate semiconductor manufacturing at the contract manufacturer
Benefits
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Sub contract manufacturing for semiconductor industries
Key process flows covered
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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
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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
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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
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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
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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
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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
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Maintain batch master record with characteristic values
Batch information cockpit
Batch Recall with batch identification (454)
Purpose and Benefits:
Purpose
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A defect batch is identified and must be recalled from customers and prospects
who have received the batch.
Benefits
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Integrated follow-up process to the former delivered batch
Return stock managed separately from the rest of your stock
Key process flows covered
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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
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Processing of defective material within a production order.
Benefits
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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
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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
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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
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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
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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
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This scenario demonstrates how to generate reports that identify production
variances and the value of WIP.
Benefits
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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
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How to execute the production variance report
How to execute the WIP report
Sales Processing with Variant Pricing
Configuration (458)
Purpose and Benefits:
Purpose
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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
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The quotation price is determined on the basis of the manufacturing costs of the
quoted product via variant conditions
Key process flows covered
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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
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This scenario describes the process of the raw material substitution functionality
in MRP for the photovoltaic industry.
Benefits
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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
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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
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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
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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
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Create Stock Transfer Request
Quality Inspection
Recording Results
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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
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Goods are No-Efficiency
• Defects Recording
• Usage Decision to Scrap No-efficiency Solar Cells
Actual Costing with Material Ledger (462)
Purpose and Benefits:
Purpose
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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
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System calculates the actual cost of materials with material ledger
CO-PA data is revaluated with actual cost
Key process flows covered
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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