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

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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

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

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

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

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

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

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.?
Regards

Closed

REGARDING DCS SYSTEM IN CEMENT INDUSTRY

HI,
I like to know what are the advantages and disvantages if i use DCS system integrated to sap pp system,my client wants to integare DCS system with sap pp. what kind of config is needed? Give me details abt that.
Regards,
seenu

Hi,
PI-PCS is a standard, open interface enabling direct integration of the SAP R/3 PP-PI System) with complementary PCS (Process Control Systems),and DCS (Distributed Control Systems).
Please refer these useful link for more details,
[DCS Inteface|https://www.sdn.sap.com/irj/sdn/go/portal/prtroot/docs/library/uuid/7efbb690-0201-0010-0b94-9a7f7dbe745c]
[INTEGRATION OF MANUFACTURING SYSTEM|https://www.sdn.sap.com/irj/sdn/go/portal/prtroot/docs/library/uuid/306a3efb-82c0-2910-69b3-89985491e1c8]
Regards,
R.Brahmankar

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,
Manoj

Hi 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

SAP implemenation in Casting Industry

Hi,
We are doing implementation for Casting Industry.
There are many stages in the process.
1) Core Manufactruing
2) Moulding
3) Motlen Metal
4) Casting-Pouring
5) Shot Blasting stage 1
6) Fettling
7) Re-shotblasting
8) Painting
9) Packing
Can any one guide me for following.
1) We should go for 9 Material codes.
or
2) Two matrial codes one before Pouring and second after pouring of metal
or
3) Any one has experience in Casting plant implementation.
There are approx 30 products each are manufactured everyday & with above 9 stages we are landing to 270 Production order a day. It will be very hactic activity for Releaseing, confirming , etc to the client.
Any one has good experience or expertise, please advice.
Regards,
Manish

Manish,
1) We should go for 9 Material codes.
Probably not, but only your client can tell you. Does he need to store inventory at any/all of the intermediate stages of production? Does he have reporting requirements about the valuation of the material(s) at various stages of production? What is the amount of time it takes to process something from RM stock to FG stock? How much commonality is there between the various components of the 30 FGs? Will any of the levels (from RM to FGs) be manufactured as MTO or MTS? Are there any quality inspection/sampling requirements at intermediate stages? What kind of material traceability will be required? You must get these and other important answers during your investigation phase of the project, before you can even begin to make a recommendation to your client.
2) Two material codes one before Pouring and second after pouring of metal
Maybe. Or, maybe even only one material number (just the FGs) from the beginning to end. Your client will decide when you give him the options.
There are approx 30 products each are manufactured everyday & with above 9 stages we are landing to 270 Production order a day. It will be very hectic activity for Releasing, confirming , etc to the client.
I guess this calculation is based on the '9-intermediate-materials-per-FGs' scenario. This may or may not be acceptable, only your client can answer. I have worked in environments where 1,000 production orders per day was acceptable, and also in environments where 30 orders a day was unacceptable.
As a side note, just because you manufacture something every day does not mean you must have an order every day. You can enter a production order for a quantity that equals 10 days worth of manufacturing capacity, and the system is just as happy as it would be if the order only consumed 1 day's capacity or 1 hour's capacity. The shop floor people just keep working on the longer orders until they are done. The size of the production or process or planned order is dependent again upon the client and his business requirements.
Many of the above decisions will have to be made in concert with requirements from functional areas other than PP. Usually during an implementation, all the functional areas will work together to come up with the solution(s) that best fit the client's requirements.
I have never worked in casting. However, SAP does have a Best Practice for Fabricated Metals that may be helpful. Here is the Building block library
http://help.sap.com/bp_fm604/FM_US/html/Content_Library_FM_EN_US.htm
Best Regards,
DB49

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

CEMENT'S INDUSTRY

Hi,
   Can any one explain, under which industy type Cement industry will come
   Ex : like Chemicals , Oil & Gas and so on
   Kindly sugest.

Hi,
Its under manufacturing Industry
some of the Modules when SAP is been used in Cement Industry are below
Business consolidation
Cost accounting
Customer relationship management
Material, warehouse, and quality management
Supply chain management
Demand planning, supply network
planning, transportation planning,and vehicle scheduling
Plant maintenance
Fleet management
Performance measurement
Human capital management activities
Business operations and activities of smaller companies
The above based are in general. to be most specific in the cement Industry the modules are
Human Capital Management Processes
http://help.sap.com/saphelp_nw70/helpdata/en/2a/77eb3cad744026e10000000a11405a/frameset.htm
Procurement and Purchasing Processes
http://help.sap.com/saphelp_nw70/helpdata/en/3a/7aeb3cad744026e10000000a11405a/frameset.htm
Production Processes
http://help.sap.com/saphelp_nw70/helpdata/en/18/7beb3cad744026e10000000a11405a/frameset.htm
Sales and Distribution Processes
http://help.sap.com/saphelp_nw70/helpdata/EN/3c/7b88408bc0bb4de10000000a1550b0/frameset.htm
Dispatching and Transportation Management Processes
http://help.sap.com/saphelp_nw70/helpdata/en/29/79eb3cad744026e10000000a11405a/frameset.htm
Hope this helps
Santosh

Maping for Cement industries

Hi friends,
which type of manufcturing to be consider for cement industry .
REM or PP PI ?
please give your suggestions
regards
Sandeep

Hi Sandeep,
Cement Industries Processes are more inclinde to PROCESS INDUSTRIES.
so you can try mapping with PP-PI.
Regards
Rehman
Reward Points if Useful

Regarding Power consumption plan annually

Hi,
We are implementing cement industry, their requirement is to Annual budget plan for Power consumption plan on section wise. How do we plan annually for power section wise. in std sap there is no provision to make annual plan in SOP.
Can any body throw me light on this.
Regards,
SAP PP

Hi,
First you need to define one more activity type as Power in your standard value key.
KS01,KS02 - Create & Change Cost centre Respectively.
KL01,KL02 - Create & Change Activity Type.
KP26 - Activity Output/Prices.
In CR01 while creating a work centre,you will be assigning a cost centre and activity types defined & valid for that cost centre.
Please refer this link also,
[Power|http://www.sap-img.com/production/set-parameter-and-work-center-formula.htm]
I think it is not possible to plan in SOP.
Hope it will solve your issue.
Regards,
R.Brahmankar

Regarding Implemenation in Cement Industry

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