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ProcessForce for SAP Business OneImprove control and visibility over production, products and process manufacturing

As a process manufacturer, depending on the level of your business complexity, an additional solution is often required to cover your specific industry requirements.

Built on the tried and tested business processes and functions provided by SAP Business One, ProcessForce combines manufacturing expertise and industry knowledge to address the challenges faced by four key sectors: consumer products (i.e. food and beverage), life sciences (i.e. pharmaceuticals), chemicals and building products.

There are some complex regulations to manage in these sectors, but ProcessForce can help your business achieve British Retail Consortium (BRC) accreditation and adhere to Food & Drug Administration (FDA) regulations.

This solution covers everything from quality control points, contamination monitoring, batch costing and equipment calibration monitoring, to managing recipes, routing, ingredients, scheduling, complaints and more.

A major challenge faced by food and beverage and pharmaceutical companies is batch traceability, which can be like looking for a needle in a haystack without the right system.

As a provider of food, we have to know exactly where our inventory comes from and where it ends up so that, if there is a need to recall a given product, we can do it easily. Thanks to ProcessForce we now have full control of our production processes, we know exactly what the costs of production are and can easily monitor batches of both finished and raw materials.

Maciej Pieprzyk Project Manager, SPA Foods

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The ProcessForce 360 degree traceability application helps you determine what batch went into what products and where, who it was sold to and where it was bought from. It easily maps all associated traceability transactions in order to understand, and better react to, a recall.

Ultimately, the system has been developed to solve the business issues process manufacturers face on a day to day basis, covering a wide spectrum of business activities and processes such as:

Product data management Bill of materials/formulations Co-product, by-product, scrap management Batch control management Production management Ingredient declaration Quality control Complaint management Product costing Production scheduling Data collection

ProcessForce mirrors SAP Business One by offering item management, bill of materials, production orders and more by warehouse.

Industry Requirements

At the heart of the ProcessForce solution resides a bill of manufacturing. This is a concept which allows process manufacturers to define the resources that are consumed and produced as part of the production process.

As a process manufacturer you need the ability to easily define your products as simple recipes or formulas, and the flexibility to manage complex recipes and define component and ingredient relationships.

Depending on the products you produce, there are other factors which have to be taken into account, for example:

Yield and factor calculations Co-product and by-products production Scrap management

Customisation

Like SAP Business One, ProcessForce can be adapted to meet your unique or changing business requirements without creating a heavy, ongoing IT burden. In fact the application uses the same tools as SAP Business One, therefore the learning and education curve is kept to a minimum.

The system’s user interface (menus, forms, dropdown lists and system messages) are available in the all the same languages that are supported by SAP Business One.

SAP for HANA

There is also a version of ProcessForce for SAP HANA, utilising embedded analytics and high-performance apps to help you work even more efficiently.

Key ProcessForce features

Product Data ManagementProcessForce provides a methodology to define all the information and compliance data that is required to fully describe a product.

Batch details - allocate batch number counters and rules such as expiry date, consume by and shelf lifeIngredients - define ingredients, nutrients, allergens and pack sizes versus serving size dataClassifications - categorise products, for example toxic and non-toxicProperties – for example, define physical and chemical characteristics

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Batch Control and TraceabilityThe batch control and traceability functions within ProcessForce provide the necessary controls to trace the genealogy of a product.

Batch and serial number - define number formats and countersSupplier batch number - record supplier’s batch number detailsExpiry/consume by date - manual or calculated date based on shelf life periodInspection date period - define the period between inspections Quality control results - actual test result values stored against batch propertiesBatch genealogy tree - forward and backward historical view Recall and audit report - list of customers and batch recall reconciliation Drill down - transaction and document traceability navigation

Quality Control This tool allows companies to manage the quality process from purchase goods receipt to customer delivery. Functionality includes:

Resources - define the resources to perform the testing e.g. microscope, x-ray machine, weight scales Items - define the materials that are required to perform the test e.g. gloves, safety glasses Frequency - define the frequency and method of testing Alerts - business alerts to communicate to inspectors when tests are required to be performed

Ingredient DeclarationAlongside allergens, percentage daily intake values and pack versus serving size, ProcessForce provides the necessary data to produce ingredient listings and declaration statements to support the process of creating product labels.

Template - define a list of nutrients or ingredients that are copied into the product master data to allow for quick data entry Business partner - record the business partner that supplies the ingredient Category - define a category to group similar ingredients e.g. sugars, fats, vegetables, oils Allergens - define a list of allergens and record which ingredients contain such allergens Alternative code - define common, scientific or Codex Alimentarius INS or EAU numbers

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Bill of Materials ProcessForce provides a simple but flexible solution for creating process orientated bill of materials.

Co-products – define a product that is usually manufactured together with another productBy-products – define material of value produced as a residual of the production processProduct formulas – define simple or formula based relationships between materials and parent productsMass replace - replace selected materials and bill of materials within another material

Product RoutingsProduct routing enables users to designate the information required to document and define the production process. Machine control setting and properties such as machine speed, temperature and pressure may also be defined, allowing for data integration to MES applications and PLC’s devices.

Define machines, labour, tooling and other such resources that are used in production Routing – the combination of operations and resources to define the total production process Production time – define queue, set-up, run time, and stock time, each with a different rate of measure Material & operation - link the consumption and production of materials to process operations

Product Costing The Product Costing element has been built to take advantage of all the costing methods found in SAP Business One, and supports the costing, analysis and financial controlling operations.

Manufacturing Orders Manufacturing Orders are used to plan, execute and record production activities.

Order dependent Bill of Material and Routing - allows for the modification of the product structure and production process to manage everyday changes that may occur within production, rather than changing company standards Schedule - forward or backwards to calculate the planned start or planned end date and time Material shortage - check availability and shortages of stock across all warehouses Traceability - review all the documents associated with picking and receiving inventory

Production Scheduling Reduce restraints on resources and time with a simple, powerful scheduling solution to manage the plant’s manufacturing orders via ‘drag and drop’ means.

The solution also automatically back-schedules sales orders that are converted to manufacturing orders to determine the start and end date and time, based on the sales order delivery date. Manufacturing orders generated from materials resource planning are also automatically scheduled when created.

Complaint Management Provide a structured method for capturing and managing the lifecycle of a complaint, regardless of whether it came from a customer, vendor or an internal department.

Track the progress of customer/supplier sample returns Search and record the batch/serial numbers Create and link a quality control test to the complaintFlag the complaint as a basis for a product recall User friendly dashboards and reporting

Data CollectionTo improve the accuracy of data, and to streamline production and inventory process flows, ProcessForce provides a fully integrated data collection and label printing solution.