How to implement Make to stock with batch management in process industry

[siva_mohapatra]

Hi SCN Gurus,

currently i have one scenario for implementation in a chemical factory. Below are the details.

• Finished product- Sodium Tungstate(ST)
• Raw Materials- Tungsten Ore Concentrate (TOC), caustic soda(NaOH)
• Auxiliary Raw Materials-

       a.       Coal      

       b.      Sulphuric Acid      

       c.       Aluminum Sulphate      

       d.      Magnesium Sulphate      

       e.       Sodium Hydro-sulphate      

       f.        Isodecanol      

       g.       Mineral Turpentine     

       h.      Ditridecylamine      

       i.         Hydrocholic Acid

• Strategy should be Make to Stock(10)
• Process- Initially they are taking raw material Tungsten Ore Concentrate(TOC) from their group company as baggage shape. Each bag having 1000KG and at the time of charging for one cycle they are charging 4 bag at a time. They have 3 operations. First leaching, second crystallisation and third blending and packaging. Finally after all process they are making Sodium Tungstate Finished product. Manually they are filling finished product into a bag upto 1100kg and then packing into a pallet. At the time of finished product packaging they are generating a batch number manually. They have no by product or co product. For each leaching operation time duration is 12hr and for crystallisation operation 8hr.
• So how to map this in SAP? Please help me in this regard.

Thanks and Regards,

Siv

[former_member184574 · Accepted solution]

Hi,

Please map the scenario as follows...

For finished product Sodium Tungstate(ST) in the material master enter planning strategy 10 in MRP 3 view and activate batch management...

In the BOM of the Sodium Tungstate(ST) enter all raw materials and Auxiliary Raw Materials as components and define their qty's as per the base qty of finished Product...

Create Resources for each operations.

Create Master recipe for Sodium Tungstate(ST)  with three operations and assign the resources accordingly.

1. leaching 2.Crystallization and 3. blending and packaging.

Maintain the standard hours and standard values accordingly...

Now create PIR's for finished Product....Run MRP...MRP will create Planned Orders..Now convert the Planned Orders to Process order when the Production is started and create batch manually in the Process order and proceed with Process order cycle like Goods issue, Confirmation and Goods Receipt...

Hope this helps...

Thanks

Kumar

[siva_mohapatra · Accepted solution]

Thanks Kumar,

I got the overall scenario but still there is a lot of confusions.

1. For batch management they want to create one batch number for each bag of final FG(ST). That must have all the assay characteristics from Laboratory test. How to map this one? Whether it will be done through standard batch management TCODE or some Z program will be required.

2. How to record consumption of bags and pallets used in packaging?

3. How to evaluate costing for auxiliary materials?

4. How to backflush all the auxiliary materials?

5. What will be lot size For both finshed product and Raw materials?

Please help me for these queries.

Thanks in advance.

Regards,

Siva

[busyaban7 · Accepted solution]

Hi Shiva,

Please find my feedback related to point 1:

a) Please can you confirm if your FG material is Quality Managed ?

b) Please can you confirm when exactly the FG sample is taken and tested?

c) Please can you also confirm if all such 1100Kg ST bags have same properties/characteristics or different? If they are all same - then what is the need for creating multiple packaging batches (1100 Kg ST) as unit batches?

d) If business is going to create multiple goods receipt inspection lots of inspection type 04 of 1100 Kg ST bags? Or something else?

One quick fix for this issue could be -  (Assumption here is that only one inspection lot is required for the entire FG (not specific to 1100 Kg ST each bags) -

i) Create in-process inspection lot of type 03 (Discrete) or 13 (REM) and perform result recording. You can check these process below -

http://scn.sap.com/thread/680335

http://scn.sap.com/thread/1333009

ii) As this in-process inspection lot is not stock relevant, all the result recording can be performed against it.

iii) Pass this Quality Inspected batch (Say as Parent Batch) through all 1100 Kg ST bags of unit batches (Say as Child Batch) and update this "Parent batch number" through one characteristic in batch classification. Make sure this characteristic is only "Display Characteristic so that manual update can't happen.

iv) Pass all 'Parent Batch' characteristics through the 1100 kg ST each Child Batches.

This above process needs to be added to your Goods Receipt enhancement.

Thanks,

Arijit

[siva_mohapatra · Accepted solution]

1. No, they do not have QM Module.

2. After blending process manually bags are filled up up to 1100 kg and from each bag sample is taken and tested in lab.

3. All the bag having different chemical properties like WO3%,Na%, Moisture% etc. After final blending process they are generating one batch number and pasting in individual bag. After Receiving laboratory test result against each bag/batch number, they are recording the result assay in a spreadsheet and sending to the Sales department. Sales department keeping the track of bag Batch number and subsequent chemical properties in a spread sheet for further customer complaint analysis.

4. They do not have QM Module at all, and all the sampling and testing done manually.

Waiting for your Response,

Thanks in advance,

Regards,

Siva Sankar

[busyaban7 · Accepted solution]

Hi Siva,

So you mean Blending and Packaging are two different processes, and 'packaging' is the final operation when all the bags get all chemical properties uniform? Or?

If GR for 1100 Kg ST is not posted during 'blending' process, then I believe you need not require one unit batch/bag at that stage. At this stage the properties may vary bag to bag and so you will need to do final blending to have uniform property across bags. So you can post finally 4 BAG and only one GR batch can be created.

If all the stock is posted at a single stretch, then it should create one batch. If already one time GR is posted and the GR batch is already created, the batch stock needs to be updated in the GR enhancement.

Thanks,

Arijit

[siva_mohapatra · Accepted solution]

Yep Both blending and packaging are different operation. After crystallisation operation sodium tungstate Crystals comes to blending machine for blending purpose. They have 7 blenders having each capacity 200kg. After blending operation, manually they transfer ST powder from blending machine to bag. Bag place in a weighing machine and they fill up the bag up to reach of 1100 kg and after filling sample taken from bag and bag packing occurs. They need to create one batch number with a specific format SYYYYMMXXXXX. After creation of batch number in SAP afterwards batch characteristics will be upload by sales persons through spreadsheed.

At the time of GRN they are generating batch number for each bag of TOC having weight of 1000kg in format of TYYYYYMMXXXXX. For one cycle of Sodium Tungstate process they are charging 4 bag of TOC-Tungsten Ore concentrate. Though its a process industry you can not link the input batch and out put finished product batch characteristics. So we have to generate a batch number at the time of partial process order confirmation, which will be 1100 kg. After creating batch number we have to upload the tested FG -ST characteristics.

So please suggest me how generate the batch number for this scenario.

Thanks and regards,

Siva