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CASO CLÍNICO
Order-Controlled Production with
Process Orders
Unit Overview
In this unit, you learn about process-order-controlled production.
Unit Objectives
After completing this unit, you will be able to:
• Explain the characteristics of order-controlled production with process orders • Describe the individual steps in process order management
• Describe the concept of process management and use a PI sheet to execute a process order
• Explain the special functions for process order management in the pharmaceutical area
Unit Contents
Lesson: Order-Controlled Production with Process Orders ... 82 Lesson: Elements, Functions, and Processing of a Process Order... 93 Exercise 3: Master Data for Order-Controlled Production with Process Orders ... 115 Exercise 4: Integration with Planning; Process Order Creation with Planned Orders ...121 Exercise 5: Process Order Release; Processing an Order with a PI Sheet ...133
Lesson: Order-Controlled Production with Process
Orders
Lesson Overview
The following topics are dealt with in this lesson: • Application areas of process orders
• Process Order-Controlled Production: Characteristics • Cross-application functional process
• Master data for process orders
Lesson Objectives
After completing this lesson, you will be able to:
• Explain the characteristics of order-controlled production with process orders
Business Example
Your company is a process manufacturing company. You produce order-related products. You are on the project team for implementing shop floor control functions based on process orders.
Application Areas of Process Orders
Process orders are used in different areas of the process manufacturing industry. Process orders can be used for various production procedures and identified, for example, according to the criteria product complexity and product stability.
Process Order-Controlled Production: Characteristics
Figure 39: Process Order-Controlled Production: Characteristics (1)
(*) Note:
In process manufacturing, there are usually increased requirements with regard to the integration of batch management and quality management within the supply chain.
Figure 40: Process Order-Controlled Production: Characteristics (2)
Notes:
The creation of process orders corresponds in many ways to the creation of production orders. The following basic functions are also supported by production orders, although they are usually used in process manufacturing:
(1) A production version must be selected for order creation.
(2) The materials in process manufacturing are typically managed in batches.
There are functions for batch number assignment for the product and for batch determination of material components.
(3) After order release, control recipes with parameters for the process control level
can be generated and sent to an external system or formatted within ECC in the form of a process instruction (PI) sheet to be processed interactively on the screen.
Hint: The synonymous terms control instruction (= control recipe) and work instruction (= process instruction) are used for production orders.
Figure 41: Process Order-Controlled Production: Characteristics (3)
Process Management
Process management is the interface between the process orders and the systems involved in process control. Due to its flexible structure, it can be connected to fully automated, partially automated, and manually operated lines.. Process management includes communication with the process control level using the PI-PCS interface or using PI sheets.
Control recipes are sent from released process orders to process control systems or are formatted in natural language as an HTML PI sheet in the SAP ECC system. In return, process messages with actual data about the process are accepted from the PI sheet or process control system.
Hint: The functions of process management are also available as of Release ECC 6.0 Enhancement Pack 3 for production orders with the following synonymous names: Process integration (= process management), control instruction (= control recipe), work instruction (= PI sheet).
SAP OPC data access (SAP ODA)
SAP OPC Data Access (SAP ODA) enables the reading and writing of data points and events using the OPC server of the ECC system. These functions are also available within the production order environment.
OPC stands for “OLE for Process Control and Openess, Productivity and Connectivity”. and is an industry standard that uses COM/DCOM technology to define manufacturer-independent interfaces for the industrial usage area. The OPC standard was designed especially for the process control level. OPC servers enable you to access different data sources (for example, process control systems, memory programmable controls, temperature sensors) and thus provide process data which can be requested by OPC clients. SAP ECC with the component SAP
ODA is an OPC server and client that can communicate with OPC servers. This
considerably simplifies the data exchange between applications.
OPC clients and OPC servers are currently PC-based systems on which a Microsoft operating system runs.
You can get further information on the OPC Foundation Internet sites http://www.opcfoundation.org and www.opceurope.org.
SAP MII
With SAP MII Manufacturing Integration and Intelligence, SAP provides an adaptive manufacturing solution for production. SAP MII gives production companies increased flexibility by linking the SAP ERP solution better with the production process level and by making near-real-time information available to employees.
SAP MII may be used in the environment for both process orders and production orders.
SAP MII uses standardized, preconfigured connectors to facilitate real-time data integration in manufacturing execution systems (MES) and SCADA systems (Supervisory Control and Data Acquisition).
Real-time analyses can be performed and their results displayed in dashboards that are browser-based and role-based. They provide important information for monitoring and supporting decisions, such as warnings, task lists, analyses, reports and near-real-time messages on production variances.
Cross-Application Functional Process
Figure 42: Cross-Application Functional Process
Process order management is a central part of a complex process chain starting with a requirement (planned or customer requirement) and ending with the goods issue of finished products.
Process order management controls the whole process of in-house production of products.
Process order execution is integrated with the functions of capacity requirements planning, costing, and inventory management. There is still integration with batch management, quality management and interfaces to process control systems and laboratory information systems.
Master Data for Process Orders
Figure 43: Master Data for Process Orders
Master data is data in the SAP system that remains unchanged over a long period of time. It contains information that is required in the same manner over and over again.
The material is the central master record in logistics. In general, SAP defines a material as a substance or commodity that is bought or sold on a commercial basis, or is used, consumed, or created in production.
A batch is a uniquely identifiable partial quantity of a material. The batches of one material are managed separately in stock. With regard to the production process, a batch is a quantity of a specific material produced during a given production run. This quantity, therefore, represents a non-reproducible unit with unique specifications.
The master data for resources describes the means of production in the production process.
A production version determines which alternative BOM in combination with which master recipe is used for process order manufacturing.
The master data of the master recipes describes the production of one or more materials in one production run without relating to a particular order.
Material BOMs describe the structure of products that are produced in a company. They are usually created and maintained from the master recipe (integrated maintenance).
Material and Batch
Figure 44: Material and Batch
In different sectors, especially in the process industry, it is necessary to work continuously through the logistical quantity and value chain using homogeneous partial quantities of a material.
In the SAP system, batch master records always depend on material master records. Batches are created for a material.
In general, the data of a material master is valid for all batches assigned to it. In contrast, a batch master record contains data that uniquely identifies the relevant batch and characterizes it as a non-reproducible unit.
The characteristic batch specifications are assigned using characteristics from the classification system in the material master and are inherited by the corresponding batch master records.
If you want a material to be produced and managed in batches, the “batch management requirement” indicator must be set in the material master record. A batch master record is usually created by the system in the background for certain business operations (such as goods receipt). Users can also create batch master records directly in master data maintenance.
Batch Management in Supply Chain Management
Figure 45: Batch Management in Supply Chain Management
Batch management is used in all areas of logistics. A batch can be traced across the whole supply chain, from the receipt of the raw material to processing in production and the creation of the final product, all the way to sales and delivery to the customer.
A batch master record can be used to assign a batch to a material at different places along the supply chain. For example, if the partial quantity of a material produced in batches leaves a production process (process order) with certain specifications, it is posted to stock with a batch number and can be uniquely identified there. If a batch is required in the supply chain with certain specifications, the batch determination function can be used to have the system find suitable batches in stock. In production, for example, batch determination is used in a process order to find and withdraw suitable material components for the product to be produced.
Demo Scenario: Ice Cream Production in Plant 1100
Lesson Summary
You should now be able to:
Lesson: Elements, Functions, and Processing of a
Process Order
Lesson Overview
In this lesson, you learn about important elements and functions of a process order as well as the typical way it is processed.
Lesson Objectives
After completing this lesson, you will be able to:
• Describe the individual steps in process order management
• Describe the concept of process management and use a PI sheet to execute a process order
• Explain the special functions for process order management in the pharmaceutical area
Business Example
Important steps in process order management are order creation, batch
determination, scheduling, availability checks, release, transfer of control recipes to process control, material withdrawal, confirmations, material delivery, and settlement. To link the process control level with process control systems and PI sheets, you must set up the process management functions. For the production of pharmaceutical products, you must implement the following functions: Order approval, material identification and material reconciliation, in-process quality inspections, batch records, digital signature.
Process Flow and Structure of Process Order
Figure 47: Processing a Process Order
The procedure involved in process order management can be divided into the following steps:
• Process planning
• Process order execution / process management • Order Completion
Many of these activities can run automatically or in the background so that manual processing of orders is minimized.
WIP determination, variance calculation, and settlement are generally periodic work for Cost Object Controlling and are usually processed in the background. A number of settings must be made (Customizing) for each step to allow for successful order processing.
Figure 48: Structure of the Process Order
Operations describe the different steps required during the production process. For a more detailed description of these steps, operations are assigned phases. Exactly one resource is assigned to an operation. At the same time, the resource assignment applies for all phases assigned to the operation.
The processing sequence of the phases is defined in relationships.
The material list is made up of components representing the materials entering and leaving the production process as well as temporarily existing materials and their planned quantities. It also defines the assignment of these material components to phases of the order according to their appearance in the process. In material quantity calculation, you define formulas to calculate the material quantities to be used or obtained in a production process, taking into account the mixing ratios of the input materials, yield ratios of the products and remaining materials as well as specific material attributes (for example, active ingredients).
Figure 49: Elements of the Process Order
Phases are used for scheduling, determining capacity requirements, and costing. The dates and capacity requirements for operations are derived from the corresponding phases.
Operations and phases can be assigned further resources or secondary resources, if required. The same business transactions can be executed for secondary resources as for phases. Secondary resources can, for example, be included in scheduling, capacity requirements planning, and costing.
A control key must be entered for both the phases and the secondary resources. The control key is used to determine how an operation or phase is to be treated in operative applications such as process orders, costing, or capacity requirements planning.
A standard value is a planned value used to carry out a phase or secondary resource, such as the execution time. Standard values are used for calculations in costing, scheduling, and capacity requirements planning.
Confirmations are entered for phases and secondary resources (however, not for operations).
Data for process management: Alternative 1:
Process instructions are structures used to transfer data from process orders to process control (PI sheets or process control systems). Process instructions are assigned to the phases of a process order. The process instructions are combined into control recipes, which are then transferred to the control recipe destinations defined for the phases.
Data for process management: Alternative 2:
From SAP R/3 ERP and SCM Extension 2.00 (EA_APPL_2.00), the data for the process management can alternatively be maintained in the form of XSteps (execution steps). Using XSteps allows you to maintain process instructions in the form of reusable and referenceable modules. A standard XStep repository is available with version management.
Order Creation Options
Figure 50: Order Creation Options
To create a process order and a planned order, a suitable production version is determined for the material based on the validity period and charge quantity range. A production version determines which alternative BOM in combination with which master recipe is used for production.
If a process order is created without a planned order, it takes the recipe and BOM from the production version.
When a planned order is converted, the production version created for it is made known to the process order and its recipe is transferred. The BOM is not reread, but rather the dependent requirements of the planned order are converted to reservations for the process order.
Integration with Planning (ECC or SCM (APO))
Figure 51: Integration with Planning (ECC or SCM (APO))
Explanations concerning integration to planning can be found in the unit “Order-Controlled Production with Production Orders”. Process orders and production orders behave in the same manner in this regard.
Order Creation with Planned Orders
Figure 52: Order Creation with Planned Orders
Explanations concerning order creation with planned orders can be found in the unit “Order-Controlled Production with Production Orders”. Process orders and production orders behave in the same manner in this regard.
Order Release Functions
Figure 53: Order Release Functions
Process orders have a status management that controls the possible processing sequence of the individual business operations. When an order is released, a status is set accordingly.
The process order must have status Released so that the business transactions for process order execution and process management can be executed.
You can release individual phases and operations, one complete order, or several orders at once.
Various activities can be triggered automatically when an order is released: • Batch number assignment for the product
• Batch determination for the material components • Material availability check
• Control recipe generation
• Generation of an inspection lot for an in-process quality check
The aims and methods of resource scheduling for process orders are the same as those for work center scheduling for production orders. They are described in the unit Order-Controlled Production with Production Orders on the pages
Detailed Scheduling (Work Center Scheduling) and Example: Graphical planning table (APO).
The availability checks for process orders are more or less the same as those for production orders. They are described in the unit Order-Controlled Production
with Production Orders on the page Availability Check for Material, Capacity, PRT. Note here that production resources/tools are not supported in the process
order.
The functions for assigning batch numbers (for the product) and for batch determination (for material components) can be used for both process orders and production orders.
A greater requirement for integration with batch management is usually found in process manufacturing.
Batch Determination
Figure 54: Batch Determination
You can use the batch determination function to assign batches with certain material specifications required for production. The system looks for batches in stock and selects them according to specific selection criteria.
Based on the selection criteria and a search strategy, the system looks for and selects suitable batches in stock. An availability check is performed at batch level.
The batch determination function is also available for the following applications: • Production order
• Repetitive manufacturing • Sales (sales order and delivery)
• Inventory management (goods movements) • Warehouse management
Process Management
Process management is the interface between PP-PI and the systems involved in process control. Due to its flexible structure, it can be connected to fully automated, partially automated, and manually operated lines.. Process management includes the following functions:
• Communication with the process control level via the PI-PCS interface or PI sheets:
– Receiving control recipes with process instructions from released process orders. The process instructions define in detail the process steps to be executed and the process data to be confirmed (using process messages).
– Manual maintenance: Displaying control recipes in natural language in the form of PI sheets that can be displayed and maintained on the screen by the process operator
– Automatic processing: Transferring control recipes to process control systems. The data is transferred via the PI-PCS interface.
– Receiving, checking, and sending process messages with actual process data from the process control system or the PI sheet. The data is transferred from the external system via the PI-PCS interface. • Reading and writing data points and events via the function SAP OPC Data
Access (SAP ODA) using the OPC server of the ECC system: – Reading and writing using a PI sheet
– Reading using the function for automatically creating process messages
Hint: The above functions are also available for production orders as of Release ECC 6.0 Enhancement Pack 3. The synonymous terms process integration (= process management), control instruction (= control recipe) and work instruction (= process instruction) are used for production orders.
HTML-Based PI Sheet
Figure 56: HTML-based PI Sheet I
Figure 57: HTML-based PI Sheet II
The SAP PI sheet favors processing on the screen, which means the process operator is to enter, confirm, or complete data interactively.
In connection with the process instructions contained in a control recipe, the PI sheet has the following elements and functions:
• Display of information about the process (control instructions, notes, and so on)
• Input fields and tables for reporting process data, input validations and signatures
• Batch determination and batch check • Process data calculation
• Reading and writing data from internal or external applications • Link to QM results recording
• Sequence definition for determining the processing sequence of phases • Comments on documentation and messages from process events
PI sheets are created in HTML layout. The browser-based PI sheet gives you the