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SAP AG 1999
Process instructions, control recipes, and process
messages
Link to process control systems
Elements of PI sheets
Contents:
Concepts of Process Management
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0.3
SAP AG 1999
Concepts of Process Management: CourseOverview Diagram
Course Overview
Navigation
Production Planning and Control for Process Industries
Make-to-Stock Production
Make-to-Stock Production in a Pharmaceutical Environment
Make-to-Order Production
Concepts of Process Management
11
22
33
44
55
66
77
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Concepts of Process Management: BusinessScenario
ExecutionExecutionProcessProcessplanningplanning
ProcessProcessmanagementmanagement
ProcessProcesscontrolcontrol
R/3 orR/3 or
external systemexternal system
PI sheet
Process
control
system
ProcessProcessorderorder
FurtherFurthermessagemessage
dest.dest.
ControlControlreciperecipe
ProcessProcessmessagesmessages
Process management is the interface between the R/3 System and the systems involved in process
control. Due to its flexible structure, it can be linked to fully automated, partially automated, and
manually operated lines. Process management comprises the following functions:
Receiving control recipes with process instructions from released process orders
Transferring control recipes to the corresponding process operators or process control systems
Displaying control recipes in natural language in the form of PI sheets that can be maintained on
the screen by the process operator
Receiving, checking, and transferring process messages with actual process data.
Manual entry of process messages.
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0.5
SAP AG 1999
At the conclusion of this topic, you will be able to:
Describe the relationship between process
instructions, control recipes, and process
messages
Name the possible types of control recipe
destinations
Describe how a control recipe is created from
the process instructions of the process order
and the control recipe destination
Process Instructions, Control Recipes, andProcess Messages: Topic Objectives (I)
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0.5.2
SAP AG 1999
Process Instructions, Control Recipes, andProcess Messages: Topic Objectives (II)
At the conclusion of this topic, you will be able to:
Describe how the information of process
instructions is displayed in a PI sheet
Describe the principle of how process messages
are created
Name the available types of message
destinations
Name important predefined message categories
in the standard system
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0.5.3
SAP AG 1999
Master recipe
Creating Control Recipes (I)
Process order
Phase 11
ControlControlreciperecipe
Proc. instr. A
Proc. instr. BProc. instr. 20
Phase 21
Proc. instr. 10
Ctrl rec. dest. A1
Send
Destination A1
Create
Create
Process instructionsare structures used to transfer data or instructions from R/3 processmanufacturing to process control. Information relevant to process control is assigned to the phases of
the order and to the control recipe destinations in the form of process instructions.
Users define process instructions according to the target system requirements.
Process management groups the process instructions into control recipes and transfers them to the
control recipe destinations specified in the process order.
Control recipes contain all the information that is relevant to the execution of a process order for
process control.
The system creates one control recipe for each control recipe destination of a process order.
You can create control recipes for the following destination types:
Process control systems in automated production lines
Process operators in manually operated production lines
In the second case, the control recipe is displayed in natural language in the form of a PI sheet that
can be maintained by the process operator.
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0.5.4
SAP AG 1999
...
Op 100
Proc. instructions
Ph 110 CRD A1
Proc. instructions
Ph 120 CRD A1
Proc. instructions
Ph 130 CRD P1
Op 300
Op 200
Proc. instructions
Ph 210 CRD P1
Proc. instructions
Ph 220 CRD P1
Proc. instructions
Ph 230 CRD P2
Master recipe
...
Op 100
Proc. instructions
Ph 110 CRD A1
Proc. instructions
Ph 120 CRD A1
Proc. instructions
Ph 130 CRD P1
Op 300
Op 200
Proc. instructions
Ph 210 CRD P1
Proc. instructions
Ph 220 CRD P1
Proc. instructions
Ph 230 CRD P2
Process order
Control recipe 1Control recipe 1
Dest. A1Dest. A1
PI sheetPI sheet
Control recipeControl recipe 2
Dest. P1Dest. P1
Process controlProcess control
systemsystem
Control recipeControl recipe 3
Dest. P2Dest. P2
Creating Control Recipes (II)
To execute an actual production process, a process order is created on the basis of a master recipe.Together with the control recipe destinations and process instructions, the operation and phase
structure is copied from the master recipe.
Once a process order has been released for production, the process instructions that are to be sent to
the same control recipe destination are grouped in a control recipe and transferred to process control.
Exactly onecontrol recipe is created for each control recipe destination.
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0.5.6
SAP AG 1999
c
Process Order 60002065Fertilizer, liquid, form SX
Phase 110
Charging
0000 PHTEXT
0000 FE_PHSTS
0010 INSTR
9999 FE_CONS9999 FE_CONS
9999 FE_PHSTE
Proc. instr.
cCRD FE
PI sheet grp. FE
ControlControlreciperecipe
PI Sheet
Destination FE
Type "PI sheet"
Status "Control recipe created"
Creating Control Recipes: Example (II)
This example shows a process order that was created based on the recipe "Fertilizer, liquid, formSX". The order was released and the control recipe was created.
Take a look at the first phase 110 of the order. In addition to the process instruction INSTR from the
recipe, the system generated the process instructions defined for the control recipe destination at the
specified position. Note:
In this example, the system did not generate the process instruction SEQDEF because the phase
did not have a preceding phase.
The system generated the process instruction FE_CONS twice because two material components
are assigned to phase 110.
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0.5.10
SAP AG 1999
Types of Message Destination
R/3 function
module:
Processmanagement
SAPoffice user:
ABAP/4 table:
External function:
Processorder
Process control PCSPI sheet
Update of data
in
R/3 modules
Information
about process
eventsBasis for
evaluations
Coordination with
external systems
Processmessage
Inventorymgmt
Qualitymgmt
Process dataevaluation
DifferentPCS
Proc. operator Scheduler
Process messages can be sent to one or more destinations for further processing.
They can be sent to the following destination types, for example:
R/3 function module
User of the SAPoffice mail system
ABAP/4 tables defined by the user
External functions (such as a process control system)
The standard system contains predefined message destinations of typeR/3 function module. You can,
for example, use these destinations to:
Update the control recipe status
Report time events for the phases of an order
Post goods movements
Report inspection result to QM
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1-6 Display your process order.
1-6-1 Display the process instruction overview for phase 0110.
Write down which process instructions are assigned to the phase in the
following table:
No. of
PI
ProcInstCat Object
type
Description
1-6-2 Interpret the result of exercise 1-6-1. To do so, compare the process
instructions in the process order with the process instructions in master
recipe T-RC9## (refer to exercise 1-4-2) and the process instructions that
have been assigned to control recipe destination FE (refer to exercise 1-4-3).
______________________________________________________
______________________________________________________
______________________________________________________
______________________________________________________
______________________________________________________
______________________________________________________
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1-9-3 Interpret the results of exercises 1-9-1 and 1-9-2. To do so, compare the
process messages created so far with the input fields that you have
maintained for phase 110 in the PI sheet.
______________________________________________________
______________________________________________________
______________________________________________________
______________________________________________________
______________________________________________________
______________________________________________________
1-10 Write down the destination types to which you can send process messages.
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
1-11 Which process messages are contained in the standard system and which functions
do they have?
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
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1-15 Display your process order.
1-15-1 Write down the statuses of phase 110.
______________________________________________________
______________________________________________________
______________________________________________________
1-15-2 Write down the confirmed start date for phase 110. Compare the confirmed
date and time with the characteristic values of the corresponding process
message.
______________________________________________________
______________________________________________________
______________________________________________________
1-15-3 Write down the confirmed activities for phase 110.
______________________________________________________
1-15-4 Write down the quantities withdrawn for material components T-RF7## and
T-RF9##. Compare the quantities with the characteristic values of thecorresponding process messages.
______________________________________________________
______________________________________________________
______________________________________________________
1-16 Send the fourth message in the message monitor.
1-17 Display your process order.
1-17-1 Write down the statuses of phase 110.
______________________________________________________
______________________________________________________
______________________________________________________
1-17-2 Write down the confirmed finish date for phase 110. Compare the
confirmed date and time with the characteristic values of the corresponding
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process message.
______________________________________________________
______________________________________________________
______________________________________________________
1-17-3 Write down the confirmed activity for phase 110. How did the system
calculate this activity?
______________________________________________________
______________________________________________________
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0.6.7 Exercises
Unit: Concepts of Process Management
Topic: Link to Process Control Systems
At the conclusion of these exercises, you will be able to:
Describe the principle of how control recipes can be transferred to a
process control system
Name the process instruction types that are available for
communicating with process control systems
Describe typical scenarios for the data exchange between the R/3
System and a process control system
You will get an overview of the different scenarios of communicating
between the R/3 System and a process control system.
OPTIONAL EXERCISES
2-1 Explain the principle of control recipe transfer from the R/3 System to a processcontrol system.
How can control recipe transfer be triggered?
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
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2-2 Which process instruction types are available for communicating with a process
control system? Explain their functions?
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
2-3 Outline the two scenarios typical for data transfer between the R/3 System and the
process control system we have dealt with in the training course.
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
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0.7.3
SAP AG 1999
PI Sheet: Process Instruction Types
Note:
PI Sheet
Comment sheet
Due to an error...Due to an error...
ProcessparameterType 1
Repeateddata requestType 2
Simpledata requestType 2
Inspection resultsrequestType 5
Dynamicfunction callType 6
Process datacalculation formulaType 4
PI sheet 1000000449 ReceivedProcess order: 1234 Material: ZXYZ Test material
Operating grp.:W01
Phase 10 / Instr.10
Heat solvent.: Temp:_________ C
Start agitator. Rot. speed:
Add material ABC. Quantity:__ ____ kgSignature:
Note:
Phase 20 / Instr. 10Check material quality. Record insp. results
Record material quantity. Call mat. qty calculation
Stop heating and slow Quantity:_ ____ kg
down agitator. Rot. speed:Signature:
Phase 30 / Instr. 10 Total quantity:
Start cooling.Record time and temperature
every hour.
Time Temperature
------- ------
You use the following types of process instructions to define the different elements of a PI sheet inthe master recipe or process order:
To define control information and additional notes, you use process parameters.
To define input fields and tables for actual data, you use process data requests. In this type of
process instruction, you also specify the message category of the message used to report the
requested values.
To define calculations and their formulas, you use process data calculation formulas. In this type
of process instruction, you also specify the message category of the message used to report the
calculated values.
To define jumps to QM inspection results recording, you use inspection results requests.
To define which functions a user can start from within the PI sheet, you use dynamic function
calls.
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0.7.4
SAP AG 1999
Instructions and Notes
NoteNote
Safety note:
Wear safety glasses, rubber
gloves, and shoes.
Avoid eye or skin contact with
solvent!
In case of an accident, use cold
water to...
Process parameter
Type 1
PI SheetPI Sheet
PI sheet 100449 Received
Process order: 1234 Material:YXYZ Test material
Operating grp.: W01
Heat solvent. Temp: ______C
Start agitator. Rot. speed:_____
Add material ABC. Quantity:_______kg
Note Signature:__
Phase 20 / Instr.10
Check material quality. Record insp. resultsRecord material quantity. Call mat. qty calculation
Stop heating and slow Quantity:____ kg
Comment sheet
To define control information and additional notes, you use process parameters.
If you have defined a note, a pushbutton is displayed below the corresponding control instruction in
the PI sheet. The text of this note is displayed on a detail screen. To access this screen, double-click
the pushbutton.
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0.7.6
SAP AG 1999
Recording Actual Values (II)
Note:
PI SheetPI Sheet
Comment sheetPI sheet 100449 Received
Process order: 1234 Material:YXYZ Test material
Phase 30 / Instr.10
Start cooling. Total quantity: ?___ KG
Read temperature and
pressure every hour.
Time Temperature Pressure
C HPa10:00 95.00 4.7
11:01 63.00 3.1
11:57 47.00 2.4
13:5 21.00 1.2
Signature: ____
Repeated process data request
Type 2
MessageMessageMessage
Message
To define tables for actual data, you use repeated process data requests.
The graphic shows how input values for a repeated data request are displayed in the PI sheet.
A message can be created for each line of the table.
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0.7.11
SAP AG 1999
Comment on Process Step
Comment
PI Sheet
PI sheet 100449 Received
Process order: 1234 Material:YXYZ Test material
Operating grp.: W01
Heat solvent. Temp: ______ C
Start agitator. Rot. speed:_____
Add material ABC. Quantity:_______ KG
Note Signature:__
Phase 20 / Instr. 10
Check material quality. Record insp. results
Record material quantity. Call mat. qty calculation
Stop heating and slow Signature: Smith
Due to an error...
Curr. positionComments
PI sheet Edit Goto Extras ...
Comment sheet
Due to an error...
Comment
Create
Isreported
to
Display/change
Comment sheet
General
Comment message
Date: 08/19/94
Time: 12:00:00
Text: "Due to ...
Order: Paste01
Operation: 1010
Phase: 0020
If unplanned events occur when processing a step in the PI sheet, you can enter a commentcontaining further explanations of the events and their effects. When creating the comment, you must
assign it to the corresponding control instruction.
Once the comment has been created, the system generates a process message of category
PI_COMM. Like all other input values, you can report this comment, by either choosing the menu
optionReport data or by signing the corresponding process step. Process management sends
comment messages to the process message record.
In the PI sheet, the first words of the comment are displayed as a short text next to the corresponding
control instruction. By double-clicking the short text, you can display the entire comment on a detail
screen. You can change the text if it has not yet been reported.
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0.8
SAP AG 1999
Concepts of Process Mangement: Unit Summary (I)
Process management coordinates the transfer of
data between the R/3 System and the process
control level.
Due to its flexible structure, process management
can be linked to automated, partially automated,
and manually operated lines.
After a process order has been released for
production, the process instructions maintained inthe process order are grouped into control
recipes.
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0.8.3 Solutions
Unit: Concepts of Process Management
Topic: Process Instructions, Control Recipes, and Process
Messages
1-1 For information on process instructions refer to the page Creating Control Recipes
(I) in your participant handbook.
1-2 For information on control recipes refer to the page Creating Control Recipes (I) in
your participant handbook.
1-3 For information on control recipe destinations refer to the page Creating Control
Recipes (I) in your participant handbook.
1-4 LogisticsProduction - ProcessMaster DataMaster RecipesRecipe
and Material ListDisplay
Recipe group: T-RC9##
1-4-1 ChooseEnter. The operation overview appears. Control recipe destination
FE has been assigned to the phases of the recipe.
1-4-2 Double-click phase number 110 and choose theProcess instructions tab.
The following process instruction has been assigned to the phase:
PI ProcInstCat Type Description
0010 INSTR 1 Control instruction with note
ChooseBack.
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1-4-3 Double-click control recipe destination FE on the operation overview.
Type: 1 "Control recipe transfer to R/3 PI sheet"
InstCat Position
Sequence
GenScope
Filter
Description
SEQDEF 05
01
05
At the start of a phase
For all predecessors
No filter
PHTEXT 05
02
00
At the start of a phase
Only one process instruction
No filter
FE_PHSTS 05
03
00
At the start of a phase
Only one process instruction
No filter
FE_CONS 06
01
01
At the finish of a phase
For all reservations
No filter
FE_PHSTE 06
0200
At the finish of a phase
Only one process instruction
No filter
ChooseExittwice.
1-5 Logistics Production - Process Process Order Process order Create With material
Material no.: T-FF9##
Production plant: 1100Process order type: PI01
ChooseEnter. The Create Process Order: Header - General Data screen appears.
Enter the following data:
Total qty: 1000 L (liters)
Start: Today
ChooseEnter. The system copies master recipe T-RC9##, schedules and releases
the order, and creates the control recipe.
Save your order and write down the order number.
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1-10 For information on message destinations, refer to the page Types of Message
Destination in your participant handbook.
1-11 For information on the business transactions, refer to the pageMessage Categories
in the Standard System in your participant handbook.
1-12 Logistics Production - Process Process Management Message Message monitor
Plant: 1100
Process order: Order number
ChooseEnter.
Double-click the message you want to display in the message monitor.
Process message category PI_PHST
Message characteristics Characteristic values
PPPI_PROCESS_ORDER Order number
PPPI_EVENT_DATE Date of event
PPPI_EVENT_TIME Time of event
PPPI_PHASE 0110
PPPI_SIGNATURE Your user
PPPI_PHASE_STATUS Start
ChooseBackand repeat the procedure for the other three message categories.
Process message category PI_CONS
Message characteristics Characteristic values
PPPI_PROCESS_ORDER Order number
PPPI_EVENT_DATE Date of eventPPPI_EVENT_TIME Time of event
PPPI_MATERIAL T-RF7##
PPPI_MATERIAL_CONSUMED Material quantity withdrawn according
to your entry in the PI sheet
PPPI_UNIT_OF_MEASURE L (liter)
PPPI_STORAGE_LOCATION 0002
PPPI_RESERVATION_ITEM Reservation item
PPPI_RESERVATION Reservation number
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1-15 Logistics Production - Process Process order Display
Process order: Order number
1-15-1 Choose Operations.
Double-click the System status field for phase 110.
CRCR Control recipe created
MCNF Manually confirmed
PCNF Partially confirmed
PRST Processing started
REL Released
ChooseBack.
1-15-2 Double-click phase number 110 on the operation overview.
Choose theDates tab.
The start date (date and time) was updated for the phase. The confirmed
dates are identical to the message characteristics PPPI_EVENT_DATE and
PPPI_EVENT_TIME for the first message of message category PI_PHST
(see exercise 1-12).
1-15-3 Choose the Qty/activities tab.
No activities have been determined yet since you have only reported the
phase start.
1-15-4 Choose theMaterials listicon.
Double-click the item numbers for the corresponding material components:
T-RF7## and T-RF9##.
The quantities withdrawn for the two materials were updated. The quantities
withdrawn are identical to the values for characteristicsPPPI_MATERIAL_CONSUMED for the messages of message category
PI_CONS. Refer to exercise 1-12.
ChooseBack.
ChooseExit.
ChooseBack.
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Solutions
Unit: Concepts of Process Management
Topic: Elements of PI Sheets
OPTIONAL EXERCISES
3-1 For information on process instructions for PI sheets, refer to the pageProcess
Instruction Types for PI Sheets in your participant handbook.
3-2 For information on PI sheets, refer to the pagePI Sheets:Process InstructionTypesand the subsequent pages in your participant handbook.