Process Industries

hi all
i am completeely new for Process industries.
i am getting a new implementation project of paint industries.
so please explain me how to create
reciepies,
resource
material master
bom ?
please help me

Hi,
Please go through following Link
Click on PDF Index. From the List get Document related to Production planning -process industries.
http://help.sap.com/printdocu/core/Print46c/en/Data/htm/english.htm
Regards,
R.Brahmankar

Similar Messages

Mile stone confirmation in process industries

HI,
Please tell how to carry out milestone confirmation in process industries any settings

In img settings required are
in transaction - OP67, see FOR THE CONTROL KEY PI01, see that confirmation field is with setting --2(Confirmation required).
for confirmation see the help document
http://help.sap.com/saphelp_47x200/helpdata/en/05/603bc6462311d182b50000e829fbfe/frameset.htm
If you are using PP-PI sheet i.e.process management then let us know
GO THROUGH THIS LINK FIRST IF PROCESS MANGEMENT IS INVOLVED
http://help.sap.com/saphelp_47x200/helpdata/en/05/603bc6462311d182b50000e829fbfe/frameset.htm

Make To Order - Process Industries

We are process order industries. And we have make to order scnerio (Tcode : cor1). Now we also want to make to order scnerio.
Please guide me what are configuration changes, what are tcodes for the same.

> We are process order industries. And we have make to order scnerio (Tcode : cor1). Now we also want to make to order scenario.
I feel now you are creating a process order directly in COR1,
IS MRP run is required? for your client?
If MRP is required, use strategy 40, System will consider both make to stock as well as MTO for that material, IF you want pure make to stock strategy then use strategy 20. that you can assign in MRP3 view of material master
then enter the sale order, the requirement will come automatically in MD04
and Run MRP in Md02
and convert the plan order in to production order in MD04 or MD40, MD41

Material staging in Process industries

Hai gurus,
I have one problem at client end.
1) The raw material is received from main stores to production stores, from there the material is issued to shop floor for
     consumption, In shop floor some material is kept as balance stock after consumption for the next day. How to handle this
     issue in SAP
2) In the same way the material related to quality ( Blending materials - Rectified spirit/colour/flavour and ageing whisky) is    received at production stores and from there it is moved to quality stores by internal transfer from there it is moved to blending section, from there the blended material issued to stores . How to handle this issue in SAP.
waiting for the the positive reply.
regards.
sekar chand

Hai Dharma,
Thanks for your reply, Based on your reply I can receive the material from main warehouse to Production main stores, but from there it is issued to production shop floor, where the( bottles) one of the rawmaterial is cleaned , washed and rinsed, so during
this proces there is lot of breakage is there. so While confirming the process order, the shop floor people will list the actual
consumption ,breakage etc, but there is also some stock of bottles left at the end of the shift for the next day prodiction at
the shop floor.
So how to handle this situation.
Regards,
sekar chand

Batch traceability in Process Industries

Hi All,
I would like to use the batch traceabilty functionality and the current industry is a process INdustry , but using the MB56 transaction gives me the batch traceabilty at the order level only. In case of our scenario we have multiple batches for single order and the order continues for several days. The output of MB56 gives all the batches for the order rather than the only required batch. How can I get the batch tracing for the components to the header material - bot top down and bottom up.
Regards,
Amol Kale

When you work in this manner, allowing the production of many batches out of one process order, then you can't get a single batch-to-batch relation because there's no such information in the system. It just doesn't exist, it was never reported, so system can't know.
If you need (because of regulatory or GMP reasons) to have a one-to-one relationship, then you need to revise the way you use process orders.
Otherwise you need to manage it in a self made side application into which you will have to report separately.
There's a new functionality called WIP Batches. You may investigate it to see if it can help you.

BOM in process industries

Hai gurus,
I have one simple query.
1) How to create BOM for process industry the following Bill of material.
a) For Producing100 LTS of RECTIFIED SPIRIT = FERT
b) Corn requirement = 1000kgs = ROH
c) Water requirement = 1000 LTS = ROH
d) Enzymes requirement = 35 ppm = ROH
e) Sulphuric acid requirement = 0.6 kgs = ROH
f) yeast requirement = 100 ppm = ROH
2) How to assign this BOM in the receipe.
waiting for the positive reply.
Regards,
sekar chand

Dear,
For this you need to go for Batch specific material unit of measurment.then
Maintain proportion unit A with proposed characteristic and batch-specific unit of measure e.g KAI(Kilogram active ingredient) in the additional data tab of material master (MM02)
Maintain quantity for the active materials in BOM with KAI as UoM provided this material has base unit of measure KG
Maintain master recipe and production version for the header material (C201)
Assign formulae to the respective excipients in master recipe
Create process order and assign a batch
Go to material list and perform batch determination for all components
Go to material quantity calculation and check the qty calculated by system
Press Save formula and Copy result button (Press Key F8) on Material Quantity Calculation screen in process order.
Hope it will help you.
Regards,
R.Brahmankar

SAP for chemical industries / process industries - is indian companies are really serious into implementing ? and any recent implementations

Really want to know leading companies who has implemented or ongoing implementation of SAP erp in chemical / Process / texitles

Hi Ragu,
SAP has been implemented in 200+ chemical companies in India. SAP has been implemented in all types of chemical companies - Public sector (like Kribhco), large companies (like Tata chemicals), Mid-size companies (like Galaxy Surfactants). SAP solutions are used in all chemical industry segments (in India) - like in Petrochemicals (Haldia Petrochemicals), Fertilizers (FACT), Paints & Coatings (Asian Paints), Agrochemicals (UPL), Industrial Gases (INOX air products). Hence I can state that Indian Chemicals companies are serious and reaping benefits from SAP implementations.
Regards Manoj Narang.

Process Industries Costing

Hi,
I am new to SAP, Implementing PPPI module for Process Industry. I have the following requirement,
Our Client Producing Oil as Finished along with 4 additional products. In that 3 products they will sold and 1 product they use for Internal purpose. So I consider 3 product as a Co product and 1 is Byproduct.
1. In the Finished Product Material master I maintained Co Product Apportionment structure. In that Apportionment structure I have idea of maintaining the Material cost proportion for finished and co product. But additionally we have the option for production cost and overhead cost. How can I maintain these cost. Is there any special setting need?
2. How can I map the By product costing.
Experts please help me.
Regards,
M25111979

Hi Pradeep,
Sorry for the late reply.
I have the following doubt,
1. We can maintain Material cost, Production cost, Overhead cost proportion for Header and Co product material in the same apportionment structure. If I maintain the same means during cost estimation I got only the Material cost proportion only not the production and overhead cost proportion.
2. In our scenario we have by product. How the cost calculation taking place, Is there any special settings required. How the By product cost taking place?
Can you please explain in details regarding the above queries.
Regards,
M25111979.

Purchase order vs planned order vs process order vs production order

Hi,
Kinldy explain difference between the Purchase order, planned order, process order and production order?
Thanks & Regards
Ravi kumar

Hi Ravi,
In simple terms:
planned order - A procurement proposal generated by the system to meet a need, this can then be converted to a production / process order (for internal procurement) or into a purchase reqn & in-turn to Purchase order (for external procurement)
Purchase order - A firmed procurement proposal which is sent to your vendor (external procurement) to supply the items as per your order
process order - A firmed procurment proposal which is used for in-house procurement, this is used in process industries eg: chemicals, oil & gas etc
production order - A firmed procurment proposal which is used for in-house procurement, this is used in discrete production industries
Based on the above am quite sure you should be able to figure out the differenced. If any doubts revert.
Regards,
Vivek

What is the process flow in MRP - MD61+MD01,MD02+MD04+COR7

Hi experts,
I need one clarification for Material requirment planning ( MRP - Process industries )
My company is newly implemented in SAP so i want some clarification in MRP side. My company flow is 3 rd level converted of FG.
1 st level - Raw paint - Samifinished
2 nd level - Tin condition - Samifinished
3 rd level - Case condition - FG
I have raised PIR in MD61 at FG code, after MRP Run planded order created at three level ( 1 st, 2nd, 3rd - level)
But what is the t.code used is correct recording MRP Run - MD01( Plant level ) OR MD02 ( Single item)
what is the t.code used for over all requirment Bill of material list ( ROH & VERP)at plant based recording purchase the material.
Kindly pls explain the flow for PIR > MRP RUN>STOCK RECUIRMENT LIST> PLANNED ORDER TO PROCESS ORDER>
Thanks,
Umapathy

Hi,
To proceed further you should firm confirm that below master data properly maintained in your system,
- Create BOM - CS01
- Create Resource - CRC1
- Create Master Recipe - C201
Now your business process starts with the requirements created in the system e.g. by MD61 in your case
Now you can run the MRP by MDBT/MD01/MD02 for your case. It is suggested to go with MD02 for better understanding on MRP behavior for single FG material.
Now You can analyze the MRP result for single FG material in MD04 transaction wherein you will get the planned order created through MRP run and also the order report for planning of below level components of BOM
Then you can further proceed for Production Execution with the help of below transactional steps:-
- COR1 - Create Process Order Manual
- COR7 - Convert Plan Order to Process Order
- COR6N/CORZ/CORR - Order Confirmation
- CORS - Cancel Confirmation
- CORT - Display Confirmation
- CO53 - Control Recipe Monitor (Optional)
- CO55/CO60 - Maintain PI Sheet (Optional)
- CO54 - Process Massage Monitor (Optional)
- MB31 - Goods Receipt For Order
- COIK / MB1A / MIGO :- Goods Issue
- KKS1/KKS2 - Calculate Varience
- CO88 - Actual settlement
- COOISPI - Order Information System
You can see the all PR created through MRP in ME5A transaction by selecting the Creation Indicator as B for MRP as shown in below screen,
And for rest of analysis you can use COOISPI report.
Regards,
Narresh

Problem during Process Order Confirmation - COR6N

Dear All,
We are into process industries
Till now we are creating different BOM for each section and different process orders for each BOM.
For example Pulverize, Acid MIXING, Continuous Rotery, Blending and Packng.
Now we have created new BOM for FG - showing all input/output of RM, SFGs. In Recipe, define operation for each section. and assign operation to material. I have attached screenshot of Recipe Operation.
During process order confirmation, system shows movement type of all material perfectly during each phase. But during confirmation of last phase system does not show 101 movemet of FGs.
I have checked in Recipe, control key is ok i.e. Automatic GR, in OPK4 setup is also correct.
We have created new BOM and Recipe. There is no change in other configuration parameter.
Thanks and Regards,
Nirav

Hi Nirav
The automatic goods receipt is defined by the operation/phase control key.
Control key PI03 has the automatic goods receipt setting by defaul.
Analyzing the screenshot I could observe that this control key is assigned to all the opration/phases, however, it should only be assigned to the last operation/phase, where the goods receipt will actually take place.
For all the previous operations/phases you should use a different control key, without automatic goods receipt, such as PI01.
BR
Caetano

Process Order Scheduling dates.........

Hi there,
             For the process order where we can do the configuarion in SPRO so that the opreation starts on the basis of earlier dates or the latest dates...
Thanks
Kaushik

Using OPUZ transaction you can Specify Scheduling parameters to operations in the Process Orders.
Use the following path via SPRO
Production Planning for Process Industries --> Process Order --> Operations -->Scheduling --> Specify Scheduling Parameters
Specify Scheduling Parameters
    In this step you define the parameters for scheduling process orders for
    each plant, order type and production scheduler. It comprises
    maintenance of
    o   scheduling levels (detailed-, production-rate and rough-cut
        scheduling)
    o   date adjustment when deadlines are exceeded
    o   scheduling control for detailed scheduling
    o   reduction
Hope this helps you.

Process Order Confirmation COR6N - By using Shift Management Functionality

Hi,
I want to confirm Operations/Phases by using T.Code COR6N.
Here i want to identify which Shift i have done confirmation by using shift management functionality.
It can be done for CORK. While doing Cofirmation for Order by using CORK, we can use this functionality.
The same i want to use for COR6N.
I have done as per following link
https://www.sdn.sap.com/irj/scn/index?rid=/library/uuid/c0fa9a04-376a-2c10-c396-86d32ac80614
Is there any option to use this functionality for COR6N ?
Pl suggest
Regards
Nag
Edited by: nag1975 on Mar 29, 2010 3:06 PM

Hi Srinath,
Go to T-code CO86 directly or go to SPRO> Production planning for process industries>process order--> operation>>confirmation and then hide the field for scrap by clicking the radio button. I think this should serve your purpose.
Please let me know if you have any issues.
Regards,
Abhijeet

Set deletion flag on process order.

Hi Friends,
My requirement is i want to set deletion flag on process order.
For this system gives error as
1. System status CRCR is active (ORD 93000112)
2. System status ORRQ is active (ORD 93000112)
Here i have solve the problem number one through transaction code BS22 (i.e. under System status I0241 -CRCR , previously LKZS - Set deletion indicator & LVMS -Mark for deletion was maintain as Forbidd now i have made it under No influence )
after saving this customization system give only error two ( System status ORRQ is active (ORD 93000112)
Same way when i try to find ORRQ but here i havenu2019t found ORRQ.
Could you plz help me.
Best Regards,
Parag Save.

Dear,
The system sets this status when you release the order, provided that the Order record required indicator is set in the order type-dependent parameters (see Customizing for Process Order)....
This setting is there in SPRO....
Production Planning for Process Industries - Process Order-Master Data-Order-Define Order type Dependent parameters...
In this you set the option Order record Required....
Requirements are that the process orders are settled, associated PI sheets, inspection lots and any linked purchase orders are complete.
Following are prerequisites for closing a process order
1 The order must have the status Released (REL) or Technically completed (TECO)
2 The order balance must be 0
3 There can be no open purchase requisitions, purchase orders.
4 There can be no future change records from confirmation processes.
.Now Calculate Overheads using Tcode : KGI2 - Individual Processing
CO43 - Collective Processing
Step to be follow,
1.Calculate WIP using Tcode : KKAX - Individual Processing
KKAO - Collective Processing
2.Calculate Variance by using Tcode : KKS2 - Individual Processing
KKS1 - Collective Processing
3.Finally do the settlement of Order in Tcode : KO88 - Individual Processing
CO88 - Collective Processing
Please refer this thread also,
https://forums.sdn.sap.com/click.jspa?searchID=17422319&messageID=5934846
The transaction COA5 (Archive Administration Preprocessing).
This will allow you to set the deletion flag
Hope this helps.
Regards,
R.Brahmankar

Process order failed to release

hi:
guru, when i released a process order,it gave message "Release rejected (check log)". then i checked log on release and found two error messages.one was Application Area (C2) messege no(009), the other is Application Area(CO) ,messege no(118). Any suggestion will be apprecaited! thanks in advance.

Hi,
Pl. check the following SPRO settings,
1) Define Order Type Dependent parameters
IMG > Production Planning for Process Industries > Process Order > Master Data > Order > Define Order Type Dependent parameters
2) Define Availability Check Define Checking Control
IMG > Production Planning for Process Industries > Process Order > Operations > Availabilty Check > Define Checking Control
These two settings should be maintained properly.
Your problem will be solved.
Srini

Process Industries

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