Lesson 4 of 6
Routings
10 min
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A routing lists the operations needed to make a product and the order they run in. Each operation names a work center, a control key and the standard values. Where the BOM answers "what goes in", the routing answers "what is done, where, and for how long."
| Operation | Work center | Control key | Setup | Per-piece time | Components allocated |
|---|---|---|---|---|---|
| 0010 Wind stator | WIND-10 | PP01 | 30 min | 10 min machine | CMC-STA-300 stator core |
| 0020 Assemble alternator | ASSY-10 | PP01 | 20 min | 30 min labor | Rotor, housing, fastener kit (backflush) |
| 0030 End-of-line test | TEST-10 | PP01 | 0 min | 5 min machine | – |
Contoso's routing for CMC-ALT-100 in plant 1710 (base quantity 1 pc). Per-piece times match the standard cost estimate: 0.5 h assembly labor and 0.25 h machine time (10 + 5 min) per alternator; setup times are illustrative.
Header and operations
A routing is created in transaction CA01 (change CA02, display CA03) or the matching Fiori app. The header carries the plant, usage, status and a lot size range. Routings are organized in groups with group counters, so one group can hold alternative sequences, for example the automated line and a manual cell.
Each operation gets a number in steps (0010, 0020 and so on, leaving room to insert), a work center, a short text and a control key. The control key decides how the operation behaves: whether it is scheduled, costed, confirmed, printed, or processed externally. In the SAP standard, PP01 is used for internal processing and PP02 for external processing by a supplier; projects often define their own keys. A wrong control key gives operations that are never costed or never need a confirmation.
Standard values
Standard values fill the slots the work center's standard value key defined. Setup is usually per order, per-piece times are per base quantity. Together with the work center formulas they drive operation dates in lead-time scheduling, capacity requirements and, through activity prices, the cost of each operation. If the routing says 30 minutes of assembly labor and the line takes 45, every alternator's standard cost is understated and every order shows a variance.
| Routing data | Feeds scheduling | Feeds capacity | Feeds costing |
|---|---|---|---|
| Work center | Formulas, shift calendar | Capacity categories | Cost center and activity types |
| Control key | Is the operation scheduled? | Does it create load? | Is it costed? |
| Setup and per-piece times | Operation duration | Capacity requirement | Activity quantities |
| Component allocation | When components are needed | – | Which operation consumes them (backflush) |
Component allocation
By default, BOM components are needed at the start of the first operation. Component allocation assigns each component to the operation that consumes it, so the stator core is needed at winding and the housing only at assembly. Allocation also matters for backflushing: a component flagged for backflush is posted automatically when the operation it is allocated to is confirmed. Allocate the fastener kit to the wrong operation and it is backflushed at winding, before anyone touched a fastener.
- ReleaseOrder released; components reserved
- Op 0010 confirmedStator core issued (allocated to 0010)
- Op 0020 confirmedRotor, housing and fastener kit issued or backflushed (allocated to 0020)
- Op 0030 confirmedFinal confirmation; goods receipt if automatic
Two header fields cause more trouble than their size suggests. The routing status must be released (for example, released for order and costing) or orders and cost estimates will not use it. The lot size range on the header must cover the quantities you actually build. A routing valid only from 1 to 99 pieces is invisible to an order for 400, and the symptom is an order with no operations rather than a clear error.
What would you do?
Kenji reports that alternator orders backflush the fastener kit when the stator winding is confirmed, a full shift before assembly. What is the cleanest fix?
- A routing lists operations with work center, control key and standard values.
- The control key decides whether an operation is scheduled, costed, confirmed or external.
- Standard values drive lead-time scheduling, capacity requirements and operation costs.
- Component allocation assigns components to operations and controls when backflush posts.
Check your understanding · not graded
Lesson check
1. Which routing element decides whether an operation is costed and confirmed?
2. Without component allocation, when are BOM components needed?
3. Why number operations in steps of ten?
4. A routing says 30 minutes of assembly labor per alternator, but the line takes 45. What happens?