Multiple Product Campaign Run SAP Best Practices for Chemicals (U.S.)

SAP Best Practices

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Purpose The purpose of this scenario is to describe business processes related to

Product Campaign within SAP ERP.

Purpose and Benefits:

Scenario Overview

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Required SAP ECC 6.00 enhancement package 3

Company roles involved in process flows Production Planner Shop Floor Specialist

SAP Applications Required:

Scenario Overview

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Color Paints Manufacturing Process

The discontinuous batch oriented Color Paint manufacturing process involves four major steps: Preassembly & Premix Pigment Grinding & Milling Product Finishing & Blending Product Filling & Packaging

Blending, Filling & Packaging are covered through existing scenarios in Best Practices for Chemicals.

Color Paint Manufacturing process (to be mapped in this scenario) is a batch oriented discontinuous process involving steps like mixing, grinding & finishing.

In the manufacture of inks and paints, a technique called a color-run is used. Color-run refers to run schedule where one manufactures the lightest color first, such as light yellow followed by the next increasingly darker color such as orange, then red and so on until reaching black and then starts over again. This minimizes the cleanup and reconfiguring of the machinery between each batch.

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Solvent (Grade A)ROH

CH-1430

Plant 1000

Discontinuous Production: Filling, Heating, Grinding, Dispersing

Additive BG99YQAI

CH-1020Pigment, YellowROH

CH-1441

Description

Mat type

Mat Nr

WM managed

QM active Batch managed

Acrylic ResinYQRM

CH-1010

Acrylic Resin(residue)

YQRM

CH-1010

Acrylic Resin(new delivery)

YQRM

CH-1010

Active Ingredient Processing

(Procurement & Manufacturing)

Paint, Yellow YQBM

CH-3100

Mixing in Storage Tank

Production Processes: Batch Production for Yellow Paint

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Solvent (Grade A)ROH

CH-1430

Plant 1000

Discontinuous Production: Filling, Heating, Grinding, Dispersing

Additive BG99YQAI

CH-1020Pigment, Black

ROH

CH-1442

Description

Mat type

Mat Nr

WM managed

QM active Batch managed

Acrylic ResinYQRM

CH-1010

Acrylic Resin(residue)

YQRM

CH-1010

Acrylic Resin(new delivery)

YQRM

CH-1010

Active Ingredient Processing

(Procurement & Manufacturing)

Paint, Black YQBM

CH-3110

Mixing in Storage Tank

Production Processes: Batch Production for Black Paint

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Run MRP MD02

Enter Planned Production QuantitiesMD61

Check Stock / Requirements ListMD04

Collective Conversion of Planned OrdersCOR8

Multiple Product Campaign Run Scenario – Mapping in SAP – Process Steps

Run MRPMD02

Check Stock / Requirements ListMD04

Capacity Overload

Yes

Adjust Production Plan

No

Capacity Overload

No

Yes Change converted Process ordersCOR2

Execute Production as per ScheduleCORK

Confirm end of a run – Final ConfirmationCORK

Cleaning Required

No

Yes

Execute Production for same color paint run as per schedule

CORK

Create Cleaning / Change-over OrderCORO

Execute Cleaning / Change-over activitiesCOR6N

Execute Production for new color paint run as per schedule

CORK

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Process Flow DiagramMultiple Product Campaign Run with MQC

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Multiple Product Campaign Run Scenario - Enhancements Start of Next color paint (like Yellow Paint) run is preceded by a cleaning of common

resource. A cleanout order is proposed when final confirmation for a processing step (phase)

identified with Cleaning Reqd checkbox ticked (defined by user fields) is being saved. This is set up through user exit - CONFPI05 (Process order conf.: Cust. spec.

enhancements when saving) Common Resource Cleaning is mapped through creation & release of Cleanout Order

(Process order without material). It is used to record and account activities & materials consumed during the cleaning process.

The Cleanout order can settled to a cost center or to paint being manufactured in next run Completion of common Resource Cleaning is ascertained through activation of User Status

– ZCL (Resource Cleaning Completed). This user status is set when the process order is fully confirmed (CNF)

Material Quantity Calculation (MQC) formula is used to calculate quantity for solvent (CH-1430) to be added in the manufacturing process. It is calculated based on active ingredient proportion in batch selected for additive (CH-1020)

Formula defined for solvent (CH-1430) ensures that solvent to paint ratio is maintained to maxm 40%. If solvent quantity calculated using Active ingredient content in batch of additive (CH-1020) is more than 40 % then keep original ratio (35%) otherwise use the calculated value. This ensures that solvent to paint ratio is maintained appropriately