Process Manufacturing ( PP-PI )

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 Process Manufacturing

Batch and recipe oriented production. 


Production planning for process industries (PP-PI) is characterized by product complexity. For many industries, it’s necessary to integrate batch management and quality management (QM) with process manufacturing in PP-PI.

The control recipe destination is the technical address to which a recipe is transferred. An operation might have several phases and each phase might have the destination. At release, the system creates Control recipes for each destination. The destination defines if it is transferred to the external system or just converted to a PI sheet.

Forms: 
  • Continous, 
  • DisContinous, 
  • Regulated. 
Process instruction sheet 
  • Process instruction 
    • Process instruction category
    • Process instruction type 
    • Process instruction characteristics 
  • Process message is to send the requested data back to SAP ERP via tRFC
    • O03C: Process message destination
    • Process message category
    • 025C: Process message characteristics 

Configuration Basics of Process Manufacturing

  • OPN1: Master recipe profile 
  • Tasklist assignment to a material type 
  • OP46: Task list status
  • COR4: order/plant-dependent settings 
  • CORY: Production scheduling profile  ( assign to material: Work scheduling )

Prepare master data for Process Industries

  • Bill of Materials: The material quantity calculation is unique to PP-PI and uses components of the material defined in its BOM.
  • The resource in process manufacturing is the same as the work center is in discrete manufacturing
  • Production Version:  which alternative BOM the system should use in combination with the master recipe for process manufacturing.
    • Header
    • Materials ( components )
    • Operations and Phases: assign activities such as production duration or labor hours at the phase level and not at the operation level
  • C201: Master Recipe: Material, Plant, Profile 
  • Characteristics

Production Planning for Process Industries

Process flow
  1. Process planning
    • Order request
    • Process order creation ( a planned order, into a process order )
    • Availability check ( ensure that the required quantities of components needed to produce the material are available )
    • Resources/Line Scheduling & Resource selection
    • Batch determination ( enable the system to perform batch determination of the components that you want to use in production )
    • Material quantity ( If you’ve enabled material quantity calculation in the master recipe of the material, the system calculates the components’ quantities. If not, it reads off the information from the material’s bill of materials (BOM) )
  2. Process management
    • Process order release
    • Order printing
    • Send control recipe ( a generated control recipe takes the form of a process instruction sheet (PI sheet )
    • Maintain PI sheet
  3. Process order execution
    • Process messages for Destinations
    • Material staging:
      • Issue raw materials and components against a process order
    • Order confirmation: at the individual phase level or at the entire process order level
    • In-process quality inspection
    • Goods receipt: send the process messages back to the SAP system
  4. Order closing
    • Variance calculation
    • Process order settlement
    • Batch record
    • Archive

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