Mapping of production process in chemical industries

[Former Member]

Hi Experts

I am new in sap process mapping for chemical industries. We want to implement SAP in our clint chemical plants.. can anybody suggest a how to mapping of process in SAP.

Our clint is manufacturing some chemical. Total process will take 15 days (from issue of material to first reactor and getting output). During this process material passed through 4 to 5 reactors. Some where we are getting intermediate material in stock. Some solvent are use in chemical process and getting back from same process. This recovered solvent is distilled in distillation plant and again used in next reaction.. Active ingredient are also coming in picture. For examples characteristics values.

Requesting clarification on below points

1. Whether we should go for REM or Process order ? ( Clint wants a batch wise costing not standard costing).

2.Whether we create a single process order for whole reaction ( 15 Days). If yes then how to receive a by products in varies stages of reaction, How cost reporting at month end.

3.or Whether we create different process order for every reactor. and what are advantages by creating reactor wise order ?

4.Whether we treat to recovered solvent as a co product or By Products? How to use equivalence number for apportionment of cost to co products.

Thanks for the Replay in Advance

Suraj

[manoj_narang]

Hi Suraj,

I would recommend that you use Process orders to map Production process. You can have one process order for 15 days covering overall process from goods issue to goods receipt. Production process steps can be defined in master recipe.

Are you able to measure / quantify material flows between reactors? You can also think of process orders for various stages of production execution like one for reactors other for solvent recovery etc. For this you need material flow data. Multiple process orders can help to cost different process steps.

Recovered Solvent can be treated as Byproduct.with separate material code. I think this recovered solvent will go to separate tank.To treat this recovered solvent - you can create a process order with Solvent as finished good.

For material flows between process steps - I would propose creating WIP materials which you can post - production and consumption against overall process order.

If you want to monitor transformation within reactor - you can review functionality called WIP Batch.

Please review and comment.

Regards

Manoj Narang