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
Similar Messages
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HI,
Can any one give the process of cement industry process details fro implemenation?
Regards,
seenuHi,
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 -
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 BalamuruganHi 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 -
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 SinghHi,
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 -
Difference Between Production Industry & Process Industry
Hi Freinds,
Hi have a query. What is the major difference between Production Industry & Process Industry?
I will give you a following example. Please carefully read it.
Take a example of TATA Motors. We all know it produces automobiles. So we will consider it as a Production Industry. But at the same time it uses the Paint to paint the vehicles is produced by it only. So can we call it as a Process Industry? If yes please explain it.
I will award deserving points accordingly for every reply.
Thanks & Regards
Saeed Arifproduction:- conversion / processing the raw materials to finished products.
differen type of industry:
job type of industry:- this is of mainly MAKE TO ORDER TYPE , suiting the particular customer requirments , after getting the order only you start doing the production
eg:- Turbine mfg by BHEL, Aircrafts and ship buildings etc.
so here your planning and costs change one order.
Repetative mfg or Batch tpe production: here the products wll be made in batches as lots eg 2000no or 5000nos qty as batches ,
here the planning and costing etc will differ from one batches to another.
eg: Automobile , apperal industry. this can be produced by strategies MAKE TO STOCK or by MAKE TO ORDER,
PROCESS INDUSTRY OR CONTINOUS TYPE OF PRODUCTIONS:
in this type of industry the Process remains same (constant) and procucts may with slight variation in composition, in this type of industy almost every thing is mechanised . this type of indstry will have LINE LAY OUT/PRODUCT LAYOUT
ie at one entry all the materials go in one line and processed and at the end of the line you will be getting finished products. the complete line will be controlled by automated sensors by using sopostigated sensors. the only problem here is that in LINE if one macine /station is have break down the complete production will comes to halt as one machine/station output is going to be input for oher staion/machine.
eg: cement, paints , food and beverages etc.
you can seggregate indstry type by materials or by the type of layout(ie mfg line)
so now coming to your doubt : TATA - AUTOMOBILES following hybrid type of laty out ie mfg of automobiles is functional layout , where there is flexibilty of planning , from paint sections on wards it follows line layout ..
so you have to call it is as product industry , intern which have line layout for cetain operations , which pertains to process industry... -
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 7Hi 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 -
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.?
RegardsClosed
-
Standerd BI Content DataSources and Cubes used for Cement industry
HI,
Kindly any one sugest the list of standerd BI Content DataSources,
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 -
Pharmaceutical Industry Process KPI's
Hi,
As a part of my work, I am conducting research on Pharma Industry processes with a view to align IT(ERP) with business.
In this regard, it would be great if some one could lead me to find good overview of the Pharma processes (such as Clinical Trial management, Compliance management), their work flow diagrams and their associated KPI's.
Thank You!
LKHi, LK.
Speaking of KPIs in practice for pharmaceutical industry, [www.*************|www.*************] may be a good resource for you. It's a catalogue of performance reports that illustrate the use of KPIs.
Examples of such reports for information security are available on: [KPIs in practice - healthcare|http://www.*************/kpi_examples_in_practice/industries/healthcare/]
They include examples from:
Teva Pharmaceutical
Johnson & Johnson
In addition to examples of performance measures, [www.*************|www.*************] also contains a user friendly library of well-documented performance measures. At the moment it lists over 3200 KPI examples, grouped in 73 functional areas, as well as 83 industries and sub-categories.
KPI examples for Pharmaceutical industry are available on this page: [KPI examples - Healthcare|http://www.*************/kpi/industries/healthcare/]
The website is updated daily with new content, so check it from time to time for additional content.
Please note that while examples of performance measures are useful to inform decisions, each performance measure needs to be selected and customized based on the objectives and priorities of each organisation.
Best regards,
Anita Liang
[www.*************|www.*************] -
Not using Backflush in Industry Process
Hi all,
First of all, I'm using Industry Process.
I wouldn't like to work with Backflush to make the material movements manually later, but I don't get it.
Master Data's:
Material master data: Backflush: "2 - Work Center decides"
Work Center (Resource), the Backflush is not marked
In the Process Order, in the BOM, the flag is not market too
The only strange thing I realised is in the Recipe, the material IS NOT assigned to any operation/phase. But, when I did the Process Order, the systems did an assignment automatically to the first operation. Is when I confirm that operation when the system did automatically the movement.
Anybody knows why is this assignament done? In a process order, the materials have to been allways assigned?
Thank's in advance!!
RogerHi,
If the Components are not assigned to any operation in the Recipe, then by default all the coponents will be assigned to the First operation in the Process Order.
If you assign your components to diffrenent operations then only they will be allocated in th Process Order.
This is the Standard behavior.
If your componants are Backflushed automatically evnthough there is no Backflush indicator is maintained in the Material Master..
Then Check the settings in OPK4 (for your Plant and order Type combination)
All Components must have Ticked in the "Generally Valid Settings" Tab page.
Hope this clarifies...
Revert for further discussion.
Regards,
Siva -
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,
Jayhi 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 -
Business Process for Cement Industry
Hello all,
I am an Indonesia
I am new to SAP
I just graduated from college, now I work in a cement company
The company uses SAP, I was placed in the department of business processes
Without going through the training process, I was asked to understand the business processes in SAP that they use. They gave me access to the development server.
But it's still hard for me to understand the business process.
Can anyone help me? from where I had to start
I apologize if any mistakes...
Thanks..Hi
That is ot correct to udnerstand the business process from SAP. it is difficult.
your company needs to provide the existing Business Process scenarios and how are they mapped to SAP with all scenarios documentation. Then, it would become easy for understand and digest and take care of issues.
Thanks,
JK -
Automobile industry process in SD
Hi All,
I am being shifted from telecom project to automobile industry project. The lead asked me to go through and learn the process in automobile industry. If anyone have worked on the same, let me know the different terms and process they use. What are the basic things i should be aware of? Please throw me some light on the same, it will be very helpful.
Thanks all in advance.
Regards
ThenmozhiYou are asking with some simple terminology to provide a detailed explanation.
As you should be aware automobile industry includes car manufacturer and component manufacturers as well and for each of these industry, configuration would differ.
From birds eye view, for car manufacturers, it would be MTO process and for component manufacturers, it would be MTS
thanks
G. Lakshmipathi -
Automile industry process?
hi friends,
i have a interview tomorrow for a automobile client, what are the automobile industry specific processes. something that is different in automotive industry as compared to other industries.
please help
skhi
Along with IS AUTOMOTIVE we activate VMS (Vehical Managment System) and also the biggest part of Is Automotive is DBM (Delear Business Managment)
There are about 17 STD scenarios in Automobile Industry which differes for OEM's, Service and Sales and Suppliers. The diff processes are
Appointment Scheduling and Workshop Planning
Parts Purchasing
Parts Stock Transferring
External Service Procurement
Customer Management
Used-Vehicle Purchasing
New Vehicle Sales with Down Payment
New Vehicle Sales with Cross Plant Stock Transfer
New Vehicle Sales with Cross Company Stock Transfer
New Vehicle Sales from Showroom
Vehicle Service and Recalls
Parts Cash Sales and Returns
Order Cancellation with Fast Order Entry
Customer Management
Vehicle Sales and Administration
Vehicle Service
Parts Management
Along with IS Automotive there is SAP IS Automotive DBM (Delear Business managment)
Not aware what is exctly your client process but as being in IS Automotive the most Important part is Service Managment, Warranty Claims
If your client is also in to vehical Leasioning then it may come to Leasining,Contracts, Mileage, Time Managment for service
Please check the link for further details
https://www.sdn.sap.com/irj/sdn/bpx-automotive
Regards
Vishal
Edited by: WISH on Apr 21, 2008 6:26 AM
Edited by: WISH on Apr 21, 2008 6:54 AM -
SAP Implementation in cement industry
Hi,
This is my second implementation in cement vertical.In earlier implementation I went with repetitive with QM.Please can you justify which will be the best suitable for cement ,REM or PP-PI.with reasons.
Regards,
ManojHi Manoj,
Better go for Repetitive Manufacturing.If customer required according to the various order go for Discrete.
Work centre consider as a line . Each cement grade must have separate BOM and routing. Accordingly must create materials.
Also, Refer this[ Very IMP Link !|http://www.sap.com/community/showdetail.epx?ItemID=14566]
Regards,
Shyamal
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