Mapping the PP process in Coatings industry

[Former Member]

Dear all,

Please explain me step-by-step how Production Planning process can be mapped in a coatings industry. Basically the production process involves a paint batch with 3 main steps :

1.Charging - where about 5 ingredients are grinded/processed for about 10 hours approx

2. Stabilisation - wherein 2 or 3 basic ingredients are added to fine tune the viscosity parameters and also to check the fineness of the grinded material

3. Discharging - where the final 10 ingredients (approx) are added, mixed, application and viscosity tested and unloaded if the parameters are satisfactory

The next batch loaded in the same machine may be same material or another colored material which follows a similar process

I want to know which of the PP-process viz, PP-PI or Discrete , is suitable for this scenario.

If PP-PI can be applied, I need the step-by-step master data to be maintained and also the end-to-end transaction and also the details in those transactions also till the final finished material is brought to unrestricted stock.

Thanks

Vel

[Former Member · Accepted solution]

Vel,

I believe that the solution you seek is supported by the SAP Best Practices for Chemicals

http://help.sap.com/saap/sap_bp/Chem_ERP605_IN/HTML/Content_Library_CHM_EN_IN.htm

In particular, you should look at the Production Model overview doc which elaborates one possible solution

http://help.sap.com/saap/sap_bp/CHEM_ERP605_IN/Documentation/BP_CH_Production_Model_EN_V1605.ppt

under the '900 Supply and Demand Planning' BP scenario.

http://help.sap.com/saap/sap_bp/BBLibrary/HTML/900_ERP605_EN_IN.htm

Best Regards,

DB49

[Former Member · Accepted solution]

Hello Friends,

Thanks for your valuable answers.I am not so experienced in PP-PI. The links above give a high level picture of what is to be done in PP-PI.It would be very helpful if you could provide me with some elaborate replies, the ABC of PP-PI : like how to create process order,Master recipes, etc.  If possible give me some snap shots of the end-to-end  step-by-step process, as if it would be helpful for beginners in PP-PI, and how could the details be correlated to the coatings industry.

Thanks

Vel

[Former Member · Accepted solution]

Vel,

SCN forums are poorly suited to be a replacement for basic training about PPPI functionality (or any other basic functionality).

Help.sap.com has a huge volume of helpful material that you can access for free.  Start with

http://help.sap.com/erp2005_ehp_06/helpdata/en/89/a419ff461e11d182b50000e829fbfe/content.htm?framese...

and work your way down the topics on the left hand side of the page.

You can also search the internet.  There are tons of documents covering all kinds of SAP topics, including PPPI.

Best Regards & Good Luck,

DB49

[Former Member]

Hi,

Thank you for the useful links.Will be more helpful if furthermore info could be provided on PP-PI.And how can these 3 processes be mapped and where in SAP :

1.Charging 

2. Stabilisation

3. Discharging

What is reference operation set and is that needed for PP-PI.

Thanks

Vel

[avinash_sharma]

Hi Vel,

As mentioned by the experts it would be very challenging work to explain the basics over here.

But let me try to put up some helpful stuffs:

You have mentioned that production will happen in batch, and since it is something related to chemical industry, it is completely suited to Process Industry !!

Production and maintenance in terms of Batches is greatly applicable to Process Industries(So you might also want to look at this part of sap --> Batch Management !)

Now,

If these three are the phase through which your raw material will be converted into final Product(say Paint !).

1.Charging 

2. Stabilisation

3. Discharging

So, what we will do is, create three Work centers for the three processes and assign appropriate Standard Values, capacity, costing and scheduling parameters to each.

Now, create a Master Recipe with three operations. Assign the three created Work-Centers to three operations in the order you want.

Let say, at the time of charging phase you mix 5 raw materials, then assign these Raw-Materials to the first operation and also maintain the quantity that is to be consumed(You can first create the BOM and then assign the BOM component to the operations in the Master Recipe).

Similar ways maintain this for the other operations.

Now you have the BOM, Master Recipe in place. we can start with our first Process Order Creation(T-Code COR1).

Certainly there are many other things to be set-up to make this process work. And It is a small space to give you all the details !!

Its better you start with your learning. And if you face any particular doubt and you do not find any relevant document, you can surely post into this forum !

Regards,

Avinash.

[Former Member]

Hi Vel,

As you have define your master data first - materials, BOM, work centers and then master recipe.

1) Define your materials -

Paint, all ingrediants added

2) BOM of pont

3) Three resources or work centers

Charging  

Stabilisation

Discharging

4) Master recipe

Either you have one master recipe with three operations and three paints

e.g. -

Operation 0010    WC Charging Base quantity

Phase 0011         WC Charging Base quantity - Running hours & other stand values

5 ingredients are grinded/processed for about 10 hours approx

Operation 0020    WC Stabiling Base quantity

Phase 0021         WC Stabiling Base quantity - Running hours & other stand values

2 or 3 basic ingredients are added to fine tune the viscosity parameters and also to check the fineness of the grinded material

Operation 0030    WC Stabiling Base quantity

Phase 0031         WC Stabiling Base quantity - Running hours & other stand values

where the final 10 ingredients (approx) are added, mixed, application and viscosity tested and unloaded if the parameters are satisfactory

Output material - Paint / coating

or

or make master recipes with each process

Then we have planning and executing steps.

Hope it is useful to you.

Regards,
Srini

[Former Member]

Hi Vel,

For Paints / Coatings type of industry and scenario you mentioned PP-PI is the best option, since it comes under process industry category.

First you need to define your master data - materials, BOM, resources (work centers) and master recipes.

Production planning is part is same - whether it PP-PI or discrete or REM. Includes demand planning and MRP mainly.

Coming to production execution part, you will have Process Orders in PP-PI. Which will have steps like Process Order create, release, GI. GR, Confirmation, TECO, CLSD and settlement. In addition to this you have process instructions, in master recipe. have PI sheet and information flow to PI sheet can be done manually or automatically from DCS, external systems with extra configuration, ABAP consultant help.

Regards,
Srini