cement updated
TRANSCRIPT
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CEMENTINDUSTRY SAP
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MANUFACTURING OF CEMENT
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SAP SOLUTIONS FOR CEMENT INDUSTRIES
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SAP SOLUTIONS FOR CEMENT INDUSTRIES
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INTEGRATED PROCESS FLOW FOR A CEMENT
PLANT
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HOW SAP INTEGRATE THE PROCESS FLOW
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PRODUCTION PLANNING & CONTROLING
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PRODUCTION PLANNING :
Sales & Operational Planning (SOP)
Demand Planning (DP)
Demand Management (DM)
Material Requirement Planning
(MRP)
Capacity Requirement Planning
(MRP)
Planned Independent
Requirement (PIR)Customer Requirement (CR)
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PRODUCTION PLANNING MASTER DATA:
Material Master
Bill of Materials (BoM)
Resource
Master Recipes
Production Version
Process Order
Goods Received
Goods Issue
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PRODUCTION PLANNING MASTER DATA:
Terms
Definition
Example
Material Master
Contains descriptions of thematerials a company procures,
produces, and stores. The material
master is the central repository of
material information (such as stock
levels) for the company.
Limestone, Cement stone, Gypsum
etc.
Bill of Materials
A bill of materials (BoM) is a list of
the parts or components that are
required to build a product. The
BoM provides the manufacturer's
part number (MPN) and the quantity
needed for each component.
Which material and how muchquantity is required to produce OPC
cement
Resource
An organizational unit that defines
where and when an operation must
be performed. The resource has an
available capacity. The activitiesperformed at or by the resources
are valuated by charge rates, that
are determined by cost centers and
activity types.
Machine , labor etc. can be treated asresource.
Master Recipe
is the description of an enterprise-
specific process in process
industries, that does not relate to aspecific order.
Crusing, Burning, Grinding, Packaging
etc.
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PRODUCTION PLANNING MASTER DATA:
Terms
Definition
Example
Production Version
A production version determineswhich alternative BOM is used
together with which task list/master
recipe to produce a material or
create a master production
schedule.
For one material, you can have
several production versions for
various validity periods and lot-size
ranges
Process order
Process orders are the main
element used for the detailed
planning and execution of process
manufacturing.
A process order describes the
production of batches (materials) ina production run or the rendering of
services. It is generated from the
master recipe and contains all the
information specified during
process planning.
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PRODUCTION PLANNING MASTER DATA:
Terms
Definition
Example
Goods receipt
When a material has been producedin a process, a goods receipt for the
order must be posted. Whether and
how you can trigger the goods
receipt posting using a process
message depends on the type of
material produced:
Goods issue
Goods Issue is basically movement
of material within the plant for
consumption/manufacturing or
outside the plant as delivery to
Customer.
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QUALITY CONTROL:
Quality Control enables recording, tracking and analysis ofproduct and process characteristics to ensure quality
compliance.
Key Benefits
Supports automatic or manual triggered inspection lots. Integrated tightly with the complete supply chain (e.g. inventory,
batch, purchasing).
Enables statistical process control (SPC) to monitor critical
product and process characteristics in the manufacturingprocess and allows instantaneous intervention.
Documents product quality to achieve regulatory compliance.
Includes integrated problem management .
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QUALITY CONTROL:
Key Functionalities
Quality Inspections
Laboratory Integration
Test equipment Interfacing
Usage Decision / Release Certificate of Analysis
Statistical Process Control
Problem Management
Test Equipment Calibration Quality Information System
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QUALITY INSPECTIONS
Comprehensive inspection processing
Goods receipt inspection .
In-process control
Post-process control Inspections at goods issue
Recurring inspections
Test equipment interfacing
Statistical process control (SPC) with integrated problemmanagement
Results recording - mobile or Web-based
Functions integrated in logistics (e.g. inventory management)
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QUALITY INSPECTION DASHBOARD