Batch management tracking issue

[former_member519660]

Hi Gurus,

There is a process which we need to implement in SAP for FMCG process industry:

Operation 1: Mixing: Enter 2200 kg of liquid mixture in mixing tank for batch A. While 200 kg is retained in mixing tank due to process limitation, only 2000 kg of batch A is moved to second operation which is cold storage.

Operation 2: Cold Storage: Cold storage tank has storage capacity of 10000 kg.

Operation 3: Packaging: Once frozen in cold storage, the product is moved to packaging facility which has a capacity of 1000 kg.

The issue is that when batch B comes to operation 2, it gets merged with batch A since cold storage has higher capacity and batch identification is not possible. We cannot stop production till batch A is completely manufactured for batch B to enter. We have to keep the process continuous.

Another issue is that, batch B can also get merged with batch A in operation 1 itself, since 200 kg is always retained in mixing tank. So even this creates batch identification problems.

How should we handle this issue for batch management to properly work?

Thanks & Best Regards,

N Sinha

[former_member42743]

This is more a manufacturing question. But from a QM perspective you only consistent product that can truly be called a batch is the frozen product. There are two options I see.

Option 1)

5 process orders to create the 5 mixing batches. Receipt these as you empty the mixer and then immediately consume each batch into the next frozen material order.

You have 1 process order to make the frozen batch. And it consumes the 5 mixing batches.

Option 2)

1 process for the frozen product.

Set the recipe up to make the full 10,000 kg. Do partial confirmations after each mixing is complete and transferred to the cold storage tank. I assume you do some testing after each mix. If a mix fails, you don't pump it over to the tank. All raw materials used in the mixer get issued to the frozen tank order, including any used to make a failed mixer batch.

Personally I would try to work out option 2.

Craig