bpp_mqc

SAP ECC 6.00

January 2008

English

PP07-Material Quantity Calculation in Blending Stage

OBT Global Inc.

(A Subsidiary Zensar Technologies Inc) 103,College Road East 2nd Floor, Princeton, NJ 08820, U.S.A

Business Process Procedure

OBT Pharma PP07 - Material Quantity Calculation in Blending Stage - BPP

Process Flow Legend

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Contents

1 Purpose................................................................................................................................................ 4

2 Prerequisites......................................................................................................................................... 5

2.1 Master Data................................................................................................................................... 5

2.1.1 Create Class Characteristics...........................................................................................................5

2.1.2 Create Class................................................................................................................................... 5

2.1.3 Create Active Material (API)............................................................................................................6

2.1.4 Create Master Inspection Characteristics.......................................................................................7

2.1.5 Create Inspection Plan.................................................................................................................... 8

2.1.6 Create Blended Material (ZBLK).....................................................................................................8

2.1.7 Create Filler Material (ROH)............................................................................................................9

2.1.8 Create a Bill of Material................................................................................................................... 9

2.1.9 Create a Master recipe.................................................................................................................. 10

2.1.10 Create Batch search strategy......................................................................................................11

3 Process Steps.................................................................................................................................... 13

3.1 Process Flow Diagram................................................................................................................13

3.2 Process Overview Table..............................................................................................................14

4 Scenario................................................................................................................................................. 15

4.1 Create a Purchase order..................................................................................................................15

4.2 Goods Receipt from Purchase order................................................................................................15

4.3 Check for the Inspection Lot.............................................................................................................16

4.4 Result Recording.............................................................................................................................. 16

4.5 Usage Decision................................................................................................................................ 17

4.6 Create a Process order.................................................................................................................... 17

4.7 Change Process order..................................................................................................................... 18

4.8 Goods issue to the order..................................................................................................................18

4.9 Completion Confirmation.................................................................................................................. 19

4.10 Goods receipt from the Order.........................................................................................................19

4.11 Technical completion.....................................................................................................................20

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Material Quantity Calculation

1 PurposeIf we use materials that are subject to batch management, you may need to take quantities and properties of specific batches into account when you perform material quantity calculations in the process order. Depending on the active ingredient concentration of a component batch, you may need, for example, different quantities of another component that is used as a filling material.

Since no batches are assigned in the master recipe, you must use the values planned in the material item when you perform calculations there. In the process order, however, you must perform the same calculation again after you have carried out batch determination due to the values of one, or in case of a batch split, several batches selected.

We use this function for a process order to visually reproduce the dependencies between the following values:

Quantity and properties of a product, such as the active ingredient proportion

Quantity and properties of material components, that is, material items and their batches

You need this function to adjust the quantities defined in the bill of material (BOM), master recipe, or process order in the following cases:

To calculate the component quantities if they are not proportional to the product quantity or if different active ingredient concentrations of batches must be taken into account

To calculate the product quantity, that is, the base quantity of the master recipe or the order quantity if it must be adjusted to modified component quantities. This may be the case if, for example, a batch of a component is always used up completely.

For this purpose we have to use both Batch specific unit of measure and Material quantity calculation through Master Recipe.

Using Batch specific unit of measure we can calculate the Active ingredient quantity in the Active material depending upon the Active ingredient percentage in that particular Batch. And using Material quantity calculation formulae defined in the Master Recipe, we can calculate the Filler material quantity in the Process order after determining the Batches of Active ingredient material.

System will subtract the quantity of the Active ingredient material from the total Ordered quantity and proposes the quantity of the Filler material which is the Excepient.

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2 Prerequisites

2.1 Master Data

2.1.1 Create Class Characteristics

UseIn this activity we create Class characteristics.

ProcedureAccess the transaction choosing one of the following navigation options:

SAP ECC Menu Cross Application components > Classification system > Master data > Characteristics

Transaction code CT04

Create three Class characteristics for Assay, LOD and Active Ingredient Percentage.

While creating Characteristics make sure that the following details are entered.

Single value

Intervals not allowed

Negative values not allowed.

Restrictions – 023 (Batch class)

Create the following Characteristics.

Class Characteristic DescriptionZASSAY ASSAY

ZLOD LOSS ON DRYING

ZACT_ING ACTIVE INGREDIENT PERCENTAGE

ResultThree Class characteristics are created.

2.1.2 Create Class

UseIn this activity we create a Class.


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SAP ECC Menu Cross Application components > Classification system > Master data > Classes

Transaction code CL02

Create a Class ZAPI_CLASS with Class type 023 and assign the following Class Characteristics.

Class Characteristic DescriptionZASSAY ASSAY

ZLOD LOSS ON DRYING

ZACT_ING ACTIVE INGREDIENT PERCENTAGE

LOBM_VFDAT SHELF LIFE

LOBM_HSDAT DATE OF PRODUCTION

While creating the Class, in the Basic data screen, in the field for Organisational area, using F4 enter the value S – Substance / Steel.

While assigning the Class characteristics, in the field for Organisational area against the Class characteristics ACT_INGR, using F4 enter the value S – Substance / Steel.

Save the Class.

ResultThe Class is created and the Characteristics are assigned.

2.1.3 Create Active Material (API)

UseIn this activity we create Active pharmaceutical ingredient.


SAP ECC Menu Logistics Materials Management Material Master Material Create (General) Immediately

Transaction code MM01

On the initial screen, enter the following values and choose Enter:

Field Description Values Comment

Material FCIP00-00

Industry sector P Pharmaceuticals

Material type ZAPI

In the Classification view assign the above created Class (ZAPI_CLASS).

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Click on Additional data tab and go to Proportion unit screen.

Enter the following details.

Field Values

Unit of measure usage A – Proportion unit

Characteristic ZACT_ING

Plan value 100 %

Batch specific unit of measure KAI (Kilogram Active Ingredient)

Leading unit of measure Select

Valuation relevant unit of measure Select

In the Quality management view activate 01 Inspection type.

Save the Material.

ResultActive material is created.

2.1.4 Create Master Inspection Characteristics

UseIn this activity we create Master Inspection Characteristics.


SAP ECC Menu Logistics Quality Management Quality Planning Basic data Inspection characteristics Create

Transaction code QS21

Create three Master Inspection characteristics for Assay, LOD and Active ingredient percentage with reference to the Class characteristics created earlier.

Master Inspection Characteristic Reference Class characteristicsASSAY ZASSAY

LOD ZLOD

ACT_INGR ZACT_INGR

While creating the third Master Inspection Characteristic ZACT_INGR, in control indicators, in the Formula area, select the radio button Calc.Charac.

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ResultMaster Inspection characteristics are created with reference to the Class characteristics.

2.1.5 Create Inspection Plan

UseIn this activity we create an Inspection plan for the Active material.


SAP ECC Menu Logistics Quality management Quality planning Inspection planning Inspection plan Create

Transaction code QP01

Create Inspection plan for the Active material and assign the three MICs which are created above.

For the third Master Inspection characteristic ACT_INGR, in the quantitative data enter the following formula.

C00010 - (100 / (100 - C00020))

This formula represents the following actual formula.

ASSAY – (100 / (100 – LOD))

Save the Inspection plan.

ResultInspection plan for the Active material is created.

2.1.6 Create Blended Material (ZBLK)

UseA new semi finished material is needed.






Material BCIP00101

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Material type ZBLK

In classification view assign a Class which contains Production date and Shelf life as Class characteristics.

2.1.7 Create Filler Material (ROH)

UseFiller material (Excepient) is created.

Procedure1. Access the transaction choosing one of the following navigation options:





Material RASP0002


Material type ZRAW

In the Classification view assign a Class with class type 023 which contains Class characteristics for SHELF LIFE & PRODUCTION DATE.

ResultFiller material (Excepient) is created.

2.1.8 Create a Bill of Material

Use In this activity we create new Bill of Material for the Blended material.

Procedure

Access the transaction using:

Menu Logistics > Production >Master data > Bill of Material> Bill of material > Material BOM > Create

Transaction code CS01

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In the initial screen enter the following details.

Field name Description User action and values Comment

Material BCIP00101

Plant 1100

BOM usage 1

Alternative BOM 1

In the General Item overview screen enter the components which are required to produce the finished / semi finished material along with quantities.

Item category Component Quantity Unit of measure

L FCIP00-00 50 KAI

L RASP0002 100 KG

For the Active material enter Unit of measure as KAI.Select the Active material, go to Extras in the main menu and click on Batch classification.

In the Batch classification screen, against the Characteristic ACT_INGR, enter the value 100%.

Go to header details and give Base quantity as 100 kg.

Click on Save button.

ResultMaterial BOM is created.

2.1.9 Create a Master recipe

Use In this activity we create new Master Recipe and Production version.

Procedure

Access the transaction using:

Menu Logistics > Production Process >Master data > Master Recipe > Recipe and Material list > Create

Transaction code C201

Create the Master Recipe and Production version.

Save the Master Recipe.

Go to Change Master Recipe.

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Go to Materials screen and click on Material Quantity Calculation button.

In the MQC screen, select the cell for Active ingredient quantity and click on Select Formula button.

In the formula definition field, enter the following formula.

CQSM(004;002)

This formula will calculate the Active ingredient percentage in the specified Batch.

Select the cell for the Filler material quantity and click on Select Formula button.

In the formula definition field, enter the following formula.

[001,001] - [004,001]

This formula will subtract the Active material quantity from the Ordered quantity and proposes the Filler material quantity.

Click on Execute button.

Save the Master Recipe.

ResultMaster Recipe and Production version are created and formulae are defined.

2.1.10 Create Batch search strategy

Use In this activity Search strategy for the Active material is created.

Access the transaction using

Menu Logistics > Central functions > Batch management > Batch Determination > Batch search strategy > For Process order > Create

Transaction code COB1

In the initial screen enter the Strategy type as CO01. Select Enter.

Choose Order type / Plant / Component. Press Enter.

Enter the Order type (ZP10) and Active material (ACT001) and press Enter.

Select the line and click on Details.

Enter the following details.

FIELD VALUE

Number of Batch splits 999

Changes allowed Select

Over delivery allowed Select

Quantity proposal 3

Display Unit of measure A

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Select the Material line and click on Selection criteria.

Enter the same class (ZAPI_CLASS) which has been assigned to the Active material.

Click on SORT button.

Enter the Sort rule – FEFO_RULE.

Click on Save button.

ResultBatch Search strategy is created.

Similarly create Batch Search strategy for the Filler material and assign FEFO rule.

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3 Process Steps

3.1 Process Flow Diagram

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3.2 Process Overview TableStep Step Name Role Transaction

CodeExpected Results

4.1 Create a Purchase order Inventory ME21N Purchase order is created

4.2 Goods Receipt from Purchase order

Inventory MIGO Goods are received from Purchase order

4.3 Check for the Inspection lot Quality control QA32 Inspection lot is created

4.4 Result recording Quality control QE51N Result recording

4.5 Usage Decision Quality control QA11 Usage decision

4.6 Create a Process order Manufacturing COR1 Process Order is created for the Material.

4.7 Change Process order Manufacturing COR2 Active and filler materials quantities are calculated.

4.8 Do Goods issue to the order Inventory Clerk MB1A Goods are issued for the Process order

4.9 Confirm the Order Manufacturing CORK Confirmation of the Process order is done.

4.10 Goods receipt from the Order Inventory Clerk MB31 Goods receipt from production is done.

4.11 Technical completion of Order Manufacturing COR2 Process order is technically completed

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4 Scenario

4.1 Create a Purchase order

UseTo create a Purchase order for the Active Material.


SAP ECC Menu Logistics > Materials Management > Purchase Order > Create

Transaction code ME21N

Enter the material, quantity and plant.

Enter Purchase organization, Purchase group and vendor.

Press Enter.

Save the transaction.

Make a note of the Purchase order number.

ResultThe Purchase Order is created for the Material.

4.2 Goods Receipt from Purchase order

UseTo receive the goods against a Purchase order.


SAP ECC Menu Logistics > Materials Management > Goods Movement > Goods Movement

Transaction code MIGO

Enter the Purchase order number and Delivery note and press Enter.

Enter the Number of containers, Batch number and manufacturing date and Post the transaction.

ResultGoods are received against the Purchase order.

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4.3 Check for the Inspection Lot

UseCheck whether the Inspection lot is created.

Access the transaction choosing one of the following navigation options:

SAP ECC Menu Logistics > Quality Management > Quality Inspection > Work list > inspection > Change data

Transaction code QA32

On the inspection Lot Selection screen, enter the necessary data, and then choose Execute.


Plant 1100

Inspection lot origin

01

Material FCIP00-00

The List shows all lots for this material. Choose the appropriate Inspection lot for the material.

ResultInspection lot for the Active material is created.

4.4 Result Recording

UseIn this activity we record the results of the Inspection lot.


SAP ECC Menu Logistics > Quality Management > Quality Inspection > Inspection Results > Result recording

Transaction code QE51N

On the inspection Lot Selection screen, enter the necessary data, and then choose Execute.


Plant 1100

Inspection lot origin

01

Material FCIP00-00

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Enter the Results in the required field for the first two chars ASSAY& LOD and valuate them.

Go to Extras in the Main menu, go to Formula and click on Calculate Formula.

According to the Formula we have entered in the Inspection plan, based on the ASSAY and LOD values, the Active Ingredient percentage will be calculated and results are displayed.

Valuate the results and Save the Results recording.

ResultResults are recorded for the inspection lot.

4.5 Usage Decision

UseIn this activity we will make Usage decision


SAP ECC Menu Logistics > Quality Management > Quality Inspection > Inspection Lot > Usage decision > Record

Transaction code QA11

On the initial screen enter the Inspection lot number.

Enter the UD code (Accepted).

Save the transaction.

After saving the UD, Batch classification will be updated and the values for all the three chars will be displayed in Batch classification data.

ResultUsage decision is made for the inspection lot.

4.6 Create a Process order

UseTo create a Process order for the Blended Material.


SAP ECC Menu Logistics > Production Process > Process Order >Process Order > Create > With Material

Transaction code COR1

Enter the Blended material number, Plant and Order type and press Enter.

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Enter the quantity and schedule the process order.

Assign a Batch number to the Blended material.

Release the Process order and Save it.

ResultThe Process Order is created for the Blended Material.

4.7 Change Process order

UseThis activity is to change the Process order for the Material.


SAP ECC Menu Logistics > Production Process > Process Order >Process Order > Change


Go to Materials overview, select the Active material and click on Batch determination tab.

As per the Active ingredient percentage values of the batches, the system will calculate and propose the changed quantity of the Active material batch.

Copy the Batches for the Active material.

Now after determining the Active material batches, in the Material overview screen, click on Material Quantity calculation button.

According to the Formulae entered in the Mater Recipe, the Active material quantity will be subtracted from the Total Ordered quantity and the Filler material quantity will be proposed.

Click on Execute button.

Now determine the Batches of Filler material.

Copy the Batches for the Filler material.

Save the Process order.

If the Active ingredient material quantity is increased according to the calculation, the system will decrease the quantity of Filler material.

ResultProcess order is changed, Material quantities are calculated and Batches are determined.

4.8 Goods issue to the order

Use

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In this activity Goods will be issued to the Process Order.


SAP ECC Menu Logistics > Material management > Inventory management >Goods movement >Goods Issue

Transaction code MB1A

Enter the movement type 261 and click on To Order button.

Enter the Process order number and click on Adapt + Details button.

While issuing goods to the Process order, the Active material will be displayed in both KG and KAI units of measure.

ResultGoods are issued to the Process Order.

4.9 Completion Confirmation

UseIn this activity we confirm the completion of the Process order.


SAP ECC Menu Logistics > Production Process > Process Order >Confirmation > Enter for Order

Transaction code CORK

Enter the Process order number and press Enter.

Enter the yield and Save the transaction.

ResultProcess Order completion is confirmed.

4.10 Goods receipt from the Order

UseProduced goods will be received from the Process order.


SAP ECC Menu Logistics > Material management > Inventory management >Goods movement >Goods Receipt > For Order

Transaction code MB31

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Enter the movement type 101, Process order number and click on Adapt + Details.

Save the Transaction.

ResultGoods are received from production against the Process order.

4.11 Technical completion

UseTo complete the Process order technically.


SAP ECC Menu Logistics > Production Process > Process Order >Process Order > Change


In the main menu go to Process order – Functions – Restrict processing – Technically complete

Choose Save.

ResultThe Process order is Technically completed.

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