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BOM, Master Recipe, Production Planning & Batch ManagementProcesses
• BOM and Master Recipe will be created for finished goods and at each intermediate
inventoried / stockable level• Manufacturing plant receives demand for Finished goods from customers or forecast
• MRP creates planned orders for production. Planned orders will be scheduled and a firm
plan is generated for a week ! "a# Rolling$.
• Planned orders are converted into process orders for e%ecution
• Batch numbers are created in &'P for raw materials( semi)finished materials and
Finished *oods.
• Finished goods are received into warehouse and shipped to customers / distribution
centers / other plants
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Production Model in SAP – Option 1( Stolberg)
Mi%ing &pra# "r# Packaging
Process Order +, semi)finished$
&emi Finished *oods
BOM - Material Recipe
Finished
*oods"emand
MRP
Manufacturing
Plant$
Planned Order for Manufacturing
Production &cheduling
and Firm Plan
endor PurchasingPurchaseOrders
Receive
Material(
'ssign Batch Vendor Batch
Number (
Expiration
Date$
Material &taging
for Production
&hipping
Finished*oods
Batch
Process Order +
Finished *oods
BOM - Material
Recipe
Finished*oods
Batch
BGS-00001 (ST-SP/555-110)
BGS-00001-0001 (ST-SP/555-110)
Pro , &MF 0 1111
Pro F* 0 ,1111 Bags$
Pro 2 F* 0 ,1111 &uper &ack$
Pro ,
Pro
Pro 2
3%ample
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Production Model in SAP – Option 1 ( Stolberg)
PRO
Standard Production model Used EU & North America
SAP Best Practice, when Semi finishedmaterials is used to fulfill multiple packagingtpes !Bags etc"
#ustomi$ed Recipe Authoring tool %uilt arecipe at Semi fished e'el
SAP planning at Semi finished le'el andconsume Semi finished plan with customerOrder
#ON
Stol%erg manufacturing is a continuous process, with no in'entoried semi fishedmaterial !(oes Not reflect at actual production
process"
Semi finished )aterial is traditionall createdwhen a material is in'entories and issues to
multiple Pack Process Order
#reate a additional process order for Semifinished
Same Batch Num%er is created for )ultiple(ifferent )aterials !Bad manufacturingPractice"
E*tra confirmation and closing of Processorder
Semi finished )aterial is a 'irtual material
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Production Model in SAP – Option 2( AS – S Br!"il)
Mi%ing &pra# "r# Packaging
Process Order +, Finished *oods$
Finished
*oods
"emand
MRP
Manufacturing
Plant$
Planned Order for Manufacturing
Production &cheduling
and Firm Plan
endor PurchasingPurchase
Orders
Receive
Material(
'ssign Batch
Vendor Batch
Number (
Expiration
Date$
Material &taging
for Production
&hipping
Finished
*oods
Batch
Finished *oods
BOM - Material Recipe
BGS-00001-0001 (ST-SP/555-110)
Pro F* 0 ,1111 Bags$Pro ,
3%ample
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Production Model in SAP – Option 2 ( AS – S Br!"il)
PRO
AS+ S Process in Bra$il
SAP Best Practice in continuousmanufacturing en'ironment
One Process Order Per run !one - to - one "relationship
SAP planning at finished material le'el andconsume plan with .inished goods customerOrder
)aster Recipe is maintained at .inishedgoods le'el
Batch Num%ering is standard SAP Best
Practice
#ON
Process is not harmoni$ed with other regions
Recipe Authoring tool
#reate a additional process order for Semifinished
Same Batch Num%er is created for / different)aterials
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#or$%&op Scope' Production ecution / S&op *loorecution
• Production Planning 4andoff to Production 3%ecution
• Process Order Release
• Read the Master Recipe / Production ersion
• 5reate a Batch 6umber
• Print &hop Floor Paper
• 5omponent 7ssues to Process order with 'utomatic batch selection F7FO• Production 5onfirmation / *oods Receipt
• Production 8ualit# and Batch 5haracteristics
• 7n)Process Re)work vs. &tock Re)9ork
• 5O*7 Processing
• :ogistical completion of Production Orders
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Production Order Execution Steps
5reate
Process
order
5omponent
'vailabilit#
check
Read Master
RecipeRelease
Process
order
'ssign Batch
6umber Print &hop
Floor Papers
Material
erification
Post goods
issue with
'utomatic
Batch
"eterminatio
n
Production
5onfirmation
5O*7
Processing
;echnicall#
complete
production
order
&ettle
production
order costs
8ualit# ;ests(
batch
derivation
Put awa# the
material
produced
Pack and
print labels
Post goods
receipt
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Production +u!lit, !nd B!tc& &!r!cteri%tic%M!nu.!cturing !lue
Stre!
RawMaterial
Receiving
8ualit#7nspectio
n
Mi%ing &pra# Packaging
7ncoming
;ruck
7nspection
Considerations:
'll trucks have
7ncoming ;ruck
7nspections and will
all be entered
directl# into &'P.5ould <ust be a
check bo% and
7ncoming 7nspection
sheet could be
scanned in.
7nspection
:ot
=sage
"ecision
7nspection
:ot7nspection
:ot
Key Decision: =sage "ecision
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OG Proce%%ing(Ontroling Good% %%ue%)
• COGI is a reprocessing log or
!oth GI"s and GR"s that ha#e
errored$
• Pro#ides a means to allo%
manuacturing #alue chain to
continue %ithout dri#ing
in#entories negati#e$
• Correct Master ata ' Batch
ata is essential$
• Extremel( important to
address COGI errors and
resol#e )S)P$
• e, eci%ion' COGI errors to
!e resol#ed during and !( the
completion o each shit * B(
+B Role$ C)-GE
M)-)GEME-+..
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APP34
#&!t i% ! P) P is a short orm or /Process e0nition ocument1$ )ll the re2uirements o a gi#en
process are gathered, re#ie%ed and appro#ed in a MS %ord document, %hichoriginates rom an appro#ed template
#&!t i% ! P*6) P34 is a short orm or /Process 3lo% diagram1$ +his is t(picall( a s%im lane diagram
5%hich is em!edded into the P346 %hich descri!es )44 the steps to complete aprocess$
#&!t i% ! *unction!l %peci7c!tion) 3unctional speci0cation is a document that descri!es the unctionalit( o the desired
!usiness re2uirements, speci0c to a !usiness %hen standard S)P does not addressthis$ +his is created onl( or appro#ed gaps 57 appro#ed gap 8 7 or more unctionalspec$6
#&!t i% ! G!p) gap is documented %hen the S)P standard unctionalit( does not address a !usiness
re2uirement$ +he Gap is documented and presented to PMO or appro#al$ Iappro#ed, the Gap is closed usuall( !( %riting unctional speci0cations to de#elopthe re2uired unctionalit(
#&!t i% # – 8 – – – – *
9 * 9or:;o%, R * Report, I * Interace, C * Con#ersion, E * Enhancement,