Keeping Production Flexible: A Guide to Alternative Sequences in SAP PP

In the world of manufacturing, adaptability is critical. Production processes may need to adjust based on factors like order size, resource availability, or unexpected equipment issues. Thankfully, SAP PP offers functionalities to cater to this need, and one such feature is the Alternative Sequence.

What is an Alternative Sequence?

An Alternative Sequence is a secondary plan within a routing that substitutes for a portion of the standard sequence. It allows you to define different operations to be executed under specific conditions.

Why Use Alternative Sequences?

There are several scenarios where alternative sequences come in handy:

• Lot-Size Dependence: Certain production steps might be more efficient for larger batches. You can define an alternative sequence containing these optimized operations that gets triggered only when the production order quantity falls within a specific lot-size range.
• Resource Availability: If a critical resource in the standard sequence becomes unavailable, you can have a readily defined alternative sequence using alternative work centers or tools.
• Process Variations: Production processes might vary slightly based on product features or customer requirements. Alternative sequences allow you to capture these variations within the routing itself.

Creating and Managing Alternative Sequences

Creating an alternative sequence involves defining the specific operations that make it up. You can also assign a lot-size range for automatic selection during production order creation. The alternative sequence connects to the standard sequence through two key points:

• Branch Point (Operation): This is the operation in the standard sequence where the system diverts to the alternative sequence.
• Return Point (Operation): This is the operation in the standard sequence where the system rejoins the standard sequence after completing the alternative sequence.

Important Considerations

• Alternative sequences cannot be modified within a production order. They are pre-defined within the routing.
• Only one alternative sequence can be active at a time.
• Lot-size ranges for alternative sequences must overlap at least partially with the overall routing lot-size range.

Conclusion

Alternative sequences are a powerful tool in SAP PP that helps maintain production flexibility. By incorporating them into your routings, you can ensure efficient and adaptable production processes that cater to various scenarios.