This article builds upon previous blog posts „From Model to Product“ and „Product Development“
to explore the PEO (Production Engineering and Operations) module within SAP S/4HANA Engineering in greater depth. The PEO Engineering module is instrumental in preparing BOMs (Bills of Materials), workflows, and production versions, ensuring accurate production specifications with comprehensive change tracking capabilities.
Seamlessly Create a Versioned Production BOM
The process starts when the designer releases a versioned design BOM. In PEO Engineering, the technologist can access and view this BOM, then use the “Copy BOM” functionality to replicate the design BOM into a versioned production BOM, making any necessary adjustments.
The versioned production BOM often differs from the design BOM. For instance, auxiliary materials like glue, lubricants, welding wires, or packaging materials may be added. Small fasteners might also be increased for contingency purposes.
Additionally, technologists can create multiple alternatives for a BOM. For example:
- Alternative 1: A component is manufactured in-house (e.g., a sheet metal blank cut internally).
- Alternative 2: The same component is purchased from an external supplier as a finished product.
Once the versioned production BOM is finalized, the technologist proceeds to create a versioned workflow.
Benefits of a Versioned Workflow in PEO
Compared to the unversioned workflow in SAP PP, PEO’s versioned workflows introduce an additional sublevel under operations called “activities.” This structure allows work at a single workstation to be divided into multiple activities, which is particularly useful for assembly operations involving multiple workers.
For example:
- In large assembly operations, different workers can handle distinct parts of the final assembly simultaneously.
- Activities can be grouped (e.g., by part) and defined as concurrent or sequential, depending on requirements.
PEO Engineering further streamlines workflow creation by allowing frequently used operations, activity groups, and activities to be saved as favorites, which can be reused in new workflows to save time.
Creating a Versioned Workflow
The technologist begins by creating a workflow header, then populates it with operations and activities. Each operation is linked to a workstation and assigned time standards. Activities can include detailed work instructions, enriched with text and images. To enhance efficiency:
- Frequently used text can be stored as standard texts, which can be copied or referenced in workflows.
- Copied text can be edited in the workflow without affecting the original standard text.
- Referenced text reflects updates to the standard text automatically based on specific parameters (e.g., version validity or production order creation date).
Additionally, activities can include documentary information records with files (e.g., drawings, models) and details about production aids (e.g., holders, lathes).
The technologist then links a specific version of the production BOM to the versioned workflow and assigns individual BOM components to relevant activities.
Integrating Quality Control into Workflows
PEO Engineering allows technologists to define control attributes for activities. These attributes specify what workers should measure or inspect, as well as the criteria to record results. Attributes can be:
- Qualitative (e.g., visual inspection)
- Quantitative (e.g., specific measurements)
Frequently used control attributes can be saved as cards for quick reuse.
The module also ensures compliance by allowing technologists to specify worker qualifications (e.g., certified welding tests) required for specific tasks. Furthermore, activities can be configured to require approval from designated personnel before workers can mark them as complete. Approvals can follow a single-step or multi-step process.
Workflow Management for Collaborative Development
When multiple technologists collaborate on a workflow, the “Manage Workflow” functionality allows the first technologist to define the subsequent steps and assign responsibilities. For instance:
- Steps may include adding operations or approving the overall workflow.
- Notifications are sent to assigned personnel via the “My Inbox” section. Each person completes their task and confirms it before the process advances.
- The final step concludes when the last assigned task is completed, at which point the workflow is released.
Automatic Production Version Creation
The final step in the technical preparation is generating the production version. This includes:
- Version code and name
- Material to be produced
- Production lot size (from-to)
- Associated production BOM and workflow
When a versioned workflow is saved, the system generates a draft production version. The technologist only needs to assign a version code and name before saving it.
Validity of Production Versions
Production versions have a defined validity period tied to specific BOM and workflow versions. When a new workflow version is created, the existing combination is terminated, and the new version takes effect. For example:
- From May 20, 2020, to August 20, 2020, version 1 of the BOM and workflow was valid.
- On August 21, 2020, version 2 of the workflow was introduced, becoming valid in combination with version 1 of the BOM.
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