How to Set Up Phantom Parts in SAP: A Step-by-Step Guide

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To set up phantom parts in SAP, follow these steps:

Step-by-Step Guide to Setting Up Phantom Parts in SAP

  1. Create a Material Master Record:
    • Go to the transaction code MM01 to create a new material master record.
    • Enter the material number and select the appropriate material type (e.g., semi-finished product).
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  1. Set the Special Procurement Key:
    • Navigate to the MRP 2 view in the material master record.
    • In the Special Procurement field, enter the value 50. This indicates that the material is a phantom assembly.
  2. Define the BOM (Bill of Materials):
    • Use the transaction code CS01 to create a BOM for the phantom assembly.
    • Enter the material number of the phantom assembly and define its components.
    • Ensure that the components are listed correctly in the BOM structure.
  3. Set the Explosion Type in BOM:
    • In the BOM, go to the Item Data section.
    • Set the Explosion Type to Phantom Assembly. This ensures that the phantom assembly is treated as a phantom during MRP runs and cost calculations.
  4. Save and Activate the BOM:
    • Save the BOM and activate it to ensure it is used in production planning and costing.

Additional Considerations

  • Phantom Assembly in MRP:
    • During an MRP run, the system ignores creating planned orders for phantom assemblies. Instead, it directly considers the components of the phantom assembly. This helps in reducing unnecessary stock levels and simplifies the planning process by focusing on the actual components needed for production.
  • Phantom Assembly in Costing:
    • Phantom assemblies themselves are not costed. Instead, their components are included in the cost estimate of the higher-level material. This ensures that the costing is accurate and reflects the actual materials used in production.
  • Handling Nested Phantom Assemblies:
    • If a phantom assembly contains another phantom assembly (nested phantom), the system will explode both levels to create planned orders for the components of both phantom assemblies.

Example Scenario

Let's say you have a high-level finished goods assembly called FG1, which includes a component called Comp1 and a higher-level phantom assembly called Phantom1. Phantom1 itself includes a lower-level phantom assembly called Phantom2, which contains components Comp3 and Comp4. Here’s how you would set it up:
  1. Create Material Master for FG1, Comp1, Phantom1, Phantom2, Comp3, and Comp4.
  2. Set Special Procurement Key to 50 for Phantom1 and Phantom2.
  3. Create BOM for FG1:
    • Include Comp1 and Phantom1 as components.
    • Set Phantom1 as a phantom assembly in its BOM.
  4. Create BOM for Phantom1:
    • Include Comp2 and Phantom2 as components.
    • Set Phantom2 as a phantom assembly in its BOM.
  5. Create BOM for Phantom2:
    • Include Comp3 and Comp4 as components.
    • Set both as normal components (no special settings needed).
By following these steps, you can effectively set up and manage phantom parts in SAP, streamlining your production planning and costing processes.