Capturing of costs in Cement industry

Hi Friends,
I need to implement SAP PP for cement manufacturing industry.They need PP implementation only for taking reports.Can anyone suggest how to model PP flow in the cement industry for taking reports and cost perspective
Regards,
Shanmugam Balamurugan

Hi Shan,
Master data creation would be.
1)material master
fert: cement(opc,ppc etc),
bulk,clinker(if these items are saleable)
halb:rawmeal, crushed Is
roh:uncrush ls,
2) prepare BOM for all finished and semi finished
3)Create resource:primary/secondary crusher,raw mill,kiln,cement mill
4)create recipe using above resorces and bom
maintain require activity,also KPI required to be captured
Create order type for plant(spro)
create order for each process with last operation PI03 n backflush indicator in order and confirm.
Hope this helps
Harris

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Standerd BI Content DataSources and Cubes used for Cement industry

HI,
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   and standerd BI Content Cubes used for Cement industry
   related projects.
Standerd BI Content Datasources and cubes for modules
SD, Product costing , Inventry, and GL.
Kindly Sugest.
Regard,
prasad.

Hi,
You can use normal InfoCubes/DataSource for the Cement Industry, recently I saw the design of the Cement Industry BI system, there also same InfoCubes and DataSourecs they used.
For Cubes and DataSource details see in SDN..
https://wiki.sdn.sap.com/wiki/display/BI/BWSDMMFIDATASOURCES
Thanks
Reddy

How to capture the cost on project of freely supplied components to vendors

Dear Friend's,
My client is sending some child components to their vendor's on free of cost basis to manufacture products like panels, tanks etc. for any particular Customer Project.
Once these products gets manufacured by vendor, they supply to client stores, from here my client is doing the delivery & billing to their customer's.
Here my client's requirement is that they wanted to capture the cost of free supplied child componenets to vendors for any particular project.
How i can capture this cost for any project..............Kindly give some input on this scenario to full fill the requirement.
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Sandeep Theurkar

Dear Sandeep
How is the client "sending" the parts to the vendor?How are you maintaining the process of sending these parts to the vendor?
Are these parts maintained in the Organization's inventory?
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How to capture Material costs, profit margins in pricing

Guys,
What is the way to capture material costs, profit margins and other sub-totals into the pricing procedure?
Thank you.

Hi
For capturing the material costs, you can use one of VPRS, EK01 or EK02 condition types. The usage of these condition types and their significance can be seen in some other thread here. There are lot of threads on these condition types.
You can also go to these links given below.
http://sap.ittoolbox.com/groups/technical-functional/sap-log-sd/condition-type-ek01-ek02-1396383
http://www.jt77.com/system-dynamics/model-08388.html
http://www.jt77.com/system-dynamics/model-05254.html
http://www.jt77.com/system-dynamics/model-04469.html
http://www.sap-img.com/sap-sd/difference-between-condition-type.htm
This should also tell you something about profit margin.
For subtotals, there is a separate column in pricing procedure and you can mention which subtotal a condition type or subtotal should correspond to. The subtotals range from 1 to 9 and then A to Z. The purpose of these subtotals can be seen by putting an F1 in that column or through some oss notes.
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Rewards if this helps.

Batch Management Implementation in Cement Industry.

Dear All
I would like to understand about Batch Management Implementation in Cement Industry.
I have some inputs on Batch Management but from Implementation in Cement Industry would like to exactly understand what are the typical scenarios for Batch Management.What should be the Batch level ie at material,client or plant level?
Has anybody worked on Batch Management Implementation in Cement Industry.?
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Closed

Average Costing in Process Industry

One of the Client requires average Costing in his Process Industry But Oracle doesnt support Average Costing in Proces Industry in R12.1.3 but supports average Costing only in Discreet Manufacturing.Please help or guide some work around immediately so that the Client could be convinced to go for Standard Costing and than for closing stock valuation some work around could be done.
Thanks & Regards in advance
V K Sharma

Important Things Involved:
O10C --- Control Recepie Destination (Clubbing of recurring PICs)
O12C --- Process Instruction Category (PICs) -- Clubbing of Process Instruction Chars to be displayed
as per requirement on PI Sheet.
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BOM:CS01
Resource:CRC1
Master Receipe:C201
Production Version:C223
PI Characteristics:Ct04/O25C
PP Process Flow:Cr01>Co53>co60/co55/co64/co67-->CO57
SOP:MC84>MC81>mc76>mc75>md63
Demand Management: MD61>MD02>MD04-->Cor1
MRP Run: MD02,MD04

Capture equipment cost in project

Dear All,
need to capture the cost of equipment which uses for project,but problem is that they take equipment from stock & uses for project work & keep it back in stock after use,
How we can capture this cost in project?
please help me out.
Regards
Gajjen

Hi,
If you are only using some tools for which requires simple functionalities, they can be defined as PRT's. In case they need to be treated as Assets with depreciation functionality, maintenance functionality as equipments ans so on, then treating them as equipments would me more appropriate. There is one more module in SAP called ETM which has enhanced functionality over PM in handling of equipments.
Usage depends on your requirement. Consult other modules too before deciding.
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Arul.

Capturing refurbishment cost in breakdown order

Dear Gurus,
If the material is being sent outside for refurbishment through a refurbishment order and that material is part of an equipment which has broken down(a breakdown order has already been raised for that equipment), the client wants the refurbishment cost to be captured against the equipment which has broken down . Same is the case with preventive maintenance. They want to capture the cost of material sent outside through refurbishment order to be captured against the equipment undergoing preventive maintenance. How can i address the above issue? Also how is it possible to send the material outside for repair through a breakdown order?
Regards,
Abhishek

See There are two way as mentioned below.
1. Just use IW36 transaction & Give main order as superior oprder on intitial screen.
2. open the main order in iw32 & follow the path as Order -
> create (special) ---> Sub order
Select the refurbishment order type to sub order.
i think this will answer ur question. if you required further more assistance please let me know.
Regards

Regarding Implemenation in Cement Industry

Dear Sir,
Could you please guide me how to mapped cement industry.Means it will be discrete, or process or Repetetive secenario.If we run MRP which MRP shoud we run Basic time sechduiling or Lead time sechduiling if so why.
What are the factors which we have to take into account while mapping the cement industries.
Regards
Bhupendra Singh

Hi,
First you need to understand complete business requirement and based on AS- IS study you can go for TO BE (Business Blueprinting) point by point.
There is no such rule for assigning components to single phase or to multiple phases. It need to be decided case to case basis for each master recipe based on business requirement.
Also PI sheets are required or not that decision solely depends on business procedures study i.e. PI sheets are basically for process control & maintaining process messages & generate control recipe at the time of process order is created.
As per my view point, REM will not suit cement industry business requirements.
Regards,
Tejas

Cement Industry Processes

Hello All,
It would be great, of one could share the possible/probable processes that might be followed in a cement industry scenario. I would appreciate if you give all the possible process//cycles w.r.t SD and I would not mind some from the procurement cycle also...for ex. it is very likely that the business is into contracting process...etc..
Rgds,
Rags.

I have listed these scenario's based on my functional experience in Cement Industry for 5 Years.
To have more details on configuration & Business Process guide, refer to link below:
Link: http://help.sap.com/
Path: SAP Best Practices --> Baseline Packages --> Based on SAP ECC 5.00 --> Select Country: for eg, Localized for India --> Technical Information --> Building Blocks --> Select Country for eg, India --> List of Basic Configuration & scenarios will be listed.
Regards,
Rajesh Banka

I want to capture quality cost, how can I do it?

What all are the basic settings I should do to capture quality cost during inspection. I mean through activity confirmation.
Control key- I activated milestone confirmation required in SPRO setting for QM02. Is anything else I need to do?
Work center- could anyone help me what exactly I need to do for confirming activity during result recording.
What is the formula need to be maintained in a step by step manner.

Hi,
You can use transaction CRQ1. Enter the plant, work center description & work center category (machine, labour) at initial screen. In the basic data tab, enter short text, person responsible, usage, standard value key. In default value key, enter control key, standard value key for set-up, machine & labour parameters. In the capacity, enter capacity category. In the scheduling category (labour, machine), capacity planner group, basic unit of measure, start time, finish time, break lengths, overload capacity, capacity utilization, no. of work centers. In costing, enter the cost center on which the costs of the work center will be adopted (for example QA department) & activity types for each activity of setup, labour & machine, in formula, enter the formula to calculate costs (for example - setup time formula for setup activity). In technical data enter, machine type, sort string, planner group. Then save the work center data. Then enter the costing data for the activity types in transaction KP26 for the cost center selected.
Assign this work center in the inspection plan operation, where you want to capture the cost. Use control key as QM04, which requires confirmation.
When you confirm the activity of inspection operation in transaction QE51N for result recording, then while saving system asks you to confirm the time required for each operation. System will calculate the costs & assign those on cost center.
Regards,
Prashant

How to capture planned cost

Dear experts ,
please help me in the following scenario.
At one of our location we have PP-PS scenario. production order is made for production in PP module.
in that location mostly JOB production is done, there about 30 % of the total cost of equipment is given to outside contractors. our problem is how to capture that cost in budget ( WBS system is being followed ) in PO WBS is assigned. we have created an activity and rate is maintained in KP26 for that activity so that planned cost is arrived at ( we have to capture the planned cost in production order) , our problem is in WBS amount is coming twice
1)as remaining order plan in WBS and the available budget amount is getting reduced
2) when the SR is made again the same amount is appearing in the commitment in WBS.and the available budget amount is reduced once again
our requirement is budget what is to be done so that budget amount is not reduced twice , we also want to capture the planned cost in production order.
Thanks and regards
sanjiv

HI,
Inorder to get all the actual costs on activity which is actually on WBS. You can do an enhancement. This enhancement should find the all POs against PR which belongs to an activity and will repost the costs that is being posted on WBS on GR to the concerned activity.
Regards,
Anjali

PP Modules Cement Industry Functional

I want to know how many work centers are normally other are using in their Cement Industry
We have
Crusher 1
Crusher 2
Raw Mill 1
Raw Mill 2
Kiln 1
Kiln 2
Cement Mill 1
Cement Mill 2
Cement Mill 3
Cement Mill 4
Packing Plant 1
Packing Plant 2
Packing Plant 3
Packing Plant 4
Packing Plant 5
Packing Plant 6
Packing Plant 7

Hi Bhaskar,
PPPI - Production planning in process industry.
It is one of the production process,where in the product is produced and controled by a DCS or one of the process controlling system, Which can be directly intergated to SAP system.
Here many level of process approvals required example ...shift operateor is given the instuction in SAP PI sheet and he does the production booking,,,which will be approved by shift incharge and then psoted to invenory, same way quality of the product also can be approved....
In the cement industry, you coordinate the communication between PP-PI and process control during the execution of a process order.
So some process contorl activity are there so you should go with PP-PI.
Hope it is now clear to you.
Regards
R.Brahmankar

Cement industry implementaion

HI,
Can any one give the process of cement industry process details fro implemenation?
Regards,
seenu

Hi,
In the mining process -
Input material is Quarry or mines where limestone is there.
From the mines, samples are brought to lab and based on soil compositation, blast sites are identified.
Drilling is done on the quarry and explosives are used.
Out of mining process - Uncrushed Limestone
You can define these items are your materials, mine as workcenter and according can make the recipe.
Further in mines, there are bunkers which carry uncrushed lime stone from blast site to crusher area.
To have any queries, pl give your e-mail id.
Hope it is clear.
Srini

Cement Industry

Hi All,
Can anyone tell what are the best practices suggested for SD point of view and also the best practised sales scenarios for Cement industry?
Regards,
Jay

hi jaya,
Some links for cement industry
http://www.essroc.com/default.aspx?pageid=183
http://www.energymanagertraining.com/cement/pdf/CementProductionProcess.pdf
http://services.eng.uts.edu.au/~johnd/MaterialsHandling/Cement.pdf
http://www.mine-engineer.com/mining/cement.htm
http://www.patentstorm.us/patents/6826448-description.html
http://www.sap.com/industries/millproducts/pdf/BWP_OV_Cement_and_Concrete.pdf
http://www.sap.com/india/company/press/press.epx?pressid=8214
http://smbzone.indiatimes.com/articleshow/25576.cms
Regards
Susrikant

Capturing of costs in Cement industry

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